3177 code practice for oh cranes and gantry cranes

IS 3177 : 1999Edition 3.2

(2003-07)

Indian Standard

CODE OF PRACTICE FOR ELECTRIC OVERHEAD TRAVELLING CRANES AND GANTRY CRANES OTHER THAN STEEL

WORK CRANES

( Second Revision )

(Incorporating Amendment Nos. 1 & 2)

ICS 53.020.20

© BIS 2004

B U R E A U O F I N D I A N S T A N D A R D SMANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG

NEW DELHI 110002

Price Group 15

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Cranes, Lifting Chains and Related Equipments Sectional Committee, HMD 14

FOREWORD

This Indian Standard (Second Revision) was adopted by the Bureau of Indian Standards, after thedraft finalized by the Cranes, Lifting Chains and Related Equipments Sectional Committee hadbeen approved by the Heavy Mechanical Engineering Division Council.

This standard covers mechanical and electrical aspects related to design, manufacture, erectionand testing of electric overhead travelling cranes and gantry cranes used in hazardous areas likeGas Group 2c. Electrical motors and electric thruster unit for brakes, limit switches, Pendant pushbutton station and panels shall be of flameproof suitable for Gas (Group 2c).

An attempt is made here to include provisions:a) to bring this standard in line with the International Standards,b) to keep higher factor of safety for hoisting mechanisms compared to travelling mechanisms

which may reduce cost of cranes without sacrificing safety, andc) to help standardization, as far as possible, relating requirements for components to basic duty

factor for class of mechanisms.

While preparing this standard assistance has been derived from various Indian, British, DIN,FEM and ISO standards to bring this standard in line with the International Standards.

As followed in the International Standards, structural provisions for cabin, walkways and meansof access are not included in this standard. It is proposed that the same should be added in IS 807.In line with this standard and new classifications now adopted, IS 807 should be modified.Provisions in IS 807 for allowable stresses, deflection criteria, wheel base to span ratio andtolerances on spans, wheel alignment, etc, be modified to bring the standard in line withInternational Standard.

The new classification of cranes now coming into effect and the classification presently in use canapproximately be compared as follows:

This edition 3.2 incorporates Amendment No. 1 (December 2000) and Amendment No. 2(July 2003). Side bar indicates modification of the text as the result of incorporation of theamendments.

For the purpose of deciding whether a particular requirement of this standard is complied with,the final value, observed or calculated, expressing the result of a test or analysis, shall be roundedoff in accordance with IS 2 : 1960 ‘Rules for rounding off numerical values ( revised )’. The numberof significant places retained in the rounded off value should be the same as that of the specifiedvalue in this standard.

Old Equivalent New Classification

I M3

II M5

III M7

IV M8

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Indian Standard

CODE OF PRACTICE FOR ELECTRIC OVERHEAD TRAVELLING CRANES AND GANTRY CRANES OTHER THAN STEEL

WORK CRANES

( Second Revision )

1 SCOPE

This code covers mechanical, electrical,inspection and testing requirements relating tothe design, manufacturing and erection ofelectric overhead travelling cranes, portal andsemi-portal cranes, single girder, double girderor mono-box type ( see Fig. 1 ). It does not coversteel work cranes which are covered inIS 4137 : 1985 and new classification for thecrane as a whole, which has been defined asfrom No. A1, A2, ...... A8 and crane mechanismhas been defined as from Nos. M1, M2, ..... M8according to IS 13834 (Part 1) : 1994.

2 REFERENCES

2.1 The Indian Standards listed in Annex F arenecessary adjuncts to this standard.

FIG. 1 TYPICAL CRANE TYPES ( Continued )

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SECTION 1 GENERAL

3 TERMINOLOGY

3.1 General

For the purpose of this standard the definitionsgiven in IS 13473 (Part 1) and following textshall apply. If there are common terms, thedefinitions given in this standard shall prevail.

3.2 Normal Service Condition

Normal service condition shall satisfy thefollowing conditions:

a) Indoor and outdoor applications shouldwith normal air of normal humidity andfree from contamination.

b) Ambient temperature should be 0°C to40°C and if the service conditions thosebeyond this, suitable derating factors shallbe applied.

c) Altitude should not exceeding 1 000 mabove mean sea level.

4 TECHNICAL INFORMATION TO BE PROVIDED

4.1 Information to be Provided Before Finalizing the Order

4.1.1 Information to be Provided by the Purchaser

All the necessary information regarding the

conditions under which the crane is to be used,together with the particulars laid down inAnnex A shall be supplied with the enquiry ororder by the purchaser to enable the cranemanufacturer to offer the most suitable craneand equipment to satisfy the duty requirementsand service conditions. The enquiry shall alsobe accompanied with a clearance diagram.

4.1.2 Information to be Provided by the Manufacturer

The manufacturer shall supply with the tenderalong with the requisite information likeregarding the construction of the craneaccording to the particulars laid down inAnnex B unless agreed otherwise by thepurchaser.

4.2 Information to be Provided Prior to Installation and Commissioning of the Crane

The manufacturer shall provide the followinginformation while commissioning of the crane:

a) General arrangement drawings showingall leading dimensions and installationdetails which were given in Fig. 2A and2B respectively;

b) Circuit and wiring diagram;

c) Operating and maintenance instructions;

d) Recommended spare parts list;

e) Test certificate;f) Details of all brought outs such as motors,

FIG. 1 TYPICAL CRANE TYPES

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RATED LOAD SPAN A B C D E G H J K L X Y

2A E. O. T. Clearance Diagram

FIG. 2 DIMENSIONS FOR E. O. T. CLEARANCE AND GANTRY CRANE CLEARANCE DIAGRAM ( Continued )

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RATED LOAD SPAN A B C D E F G H J K L M N P Q R S T U

2B Gantry Crane Clearance Diagram

FIG. 2 DIMENSIONS FOR E. O. T. CLEARANCE AND GANTRY CRANE CLEARANCE DIAGRAM

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gear box, brakes, etc, along with theirmanufacturer’s name, model number,address, etc; and

g) Should also provide full details of the wirerope used such as construction, length,grade and manufacturer’s name, etc.

5 IDENTIFICATION AND LOAD INDICATION

5.1 Both sides of the crane shall bear one ormore plaques along with permanent inscriptionon which the following shall be inscribed:

a) Manufacturer’s name and trade-mark,

b) The safe working loads of eachindependent hoist of the crane, and

c) Purchaser’s crane code number (ifrequired by the purchaser).

These plaques should be readily legible fromthe ground floor level or operating level andshall be accessible for maintenance.

5.2 A small plaque shall be located in aprominent position in the cab or at theapproachable portion of the crane bearing thefollowing inscription:

a) Manufacturer’s name and trade-mark,

b) Manufacturer’s serial number,

c) Year of manufacture, and

d) Safe working load.

6 CLASSIFICATION

The classification of the crane as a whole andof each mechanism shall be based onthe information provided by the purchaserand shall be determined in accordance withIS 13834 (Part 1) and IS 13834 (Part 5)respectively.

NOTES

1 The classification of the individual motions of a cranemay not necessarily be the same as those of cranestructure. The classification of one motion of a cranemay differ from that of another motion of the samecrane.

2 In the case where a crane mechanism is required toperform a duty that falls beyond the GroupClassification M8, either the mechanism shall bedesigned for higher hook load or other parameters shallbe changed so that it satisfies requirement for theGroup Classification M8.

SECTION 2 MECHANICAL

7 DESIGN OF CRANE MECHANISM

7.1 General

The design of the component parts of themechanism relating to each crane motion shall

be included with due allowance for the effects ofthe duty which the mechanism will perform inservice. The design of the component partsshall be in accordance with the provisions givenin this section.

7.2 Impact Factor

The impact factor applied to the motion of thehook in a vertical direction covers inertia forcesincluding shock. In calculating the live loads inthe components of the mechanism, the ratedhook load shall be multiplied by the impactfactor, given in Table 1 for various classes ofmechanism which were given below :

7.3 Loadings to be Considered in the Design of Mechanisms

7.3.1 Loads

The following loadings shall be taken intoaccount when designing a mechanism and itscomponents:

Table 1 Impact Factor for Structural Design

Group Classification of the Mechanism

Impact Factor

M1 1.06

M2 1.12

M3 1.18

M4 1.25

M5 1.32

M6 1.40

M7 1.4

M8 1.50

Rd = loads due to the dead weight of themechanism or component and deadweight of those parts of the craneacting on the mechanism or thecomponent under consideration.

Rh = loads due to the weight of the hookload with reference to Fig. 3 and alsoit is defined as SWL of the hook.

Rhi = loads due to the weight of the hookload increased by the impact factorgiven in 7.2.

Rm = dynamic loading arising from theacceleration or braking of themotion and from skewing interactionbetween the crane and track.These loads include those loads

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7.3.2 Loading Condition and LoadCombinations

Each mechanism of the crane shall be designedto operate satisfactorily under the mostunfavourable combination of loadings that canoccur under different conditions and that couldalso actually occur in practice.

Case I Normal service without windwhere crane capacity equal to Rh

a) Vertical motion : hoisting or lowering

1) Rd + Rh + Rm + Rf

2) Rd + Rhi

b) Horizontal motion : traverse or travel

Rd + Rh + Rm + Rf

Case II Normal service with wind

a) Vertical motion : hoisting or lowering

1) Rd + Rh + Rm + Rf + Rw1

2) Rd + Rhi + Rw1


Rd + Rh + Rm + Rf + Rw1

Case III Crane out of service

a) Vertical motion : hoisting or lowering notapplicable.


Rd + Rw2

Case IV Exceptional loading condition

The combination of loads to be considered forthis case of loading will depend upon the type ofcrane, application and the crane motion.Account shall be taken of any loading conditionthat are known to apply but which are notcovered under the other three cases of loading.A few cases of exceptional loading are asfollows:

a) Loads due to collision of cranes with eachother or with end stoppers that is bufferloads.

b) Loads due to testing of cranes.

c) Erection loads.

FIG. 3 ILLUSTRATION OF TYPICAL ATTACHMENTS IN RELATION TO SAFE WORKING LOAD

due to the below said reasons:

a) inertia of the mechanism,associated crane parts and hookload,

b) its prime mover and brakes, and

c) concurrent operation of othermotions, etc, as applicable.

Rf = loads arising from frictional forces.

Rw1 = loads due to the service wind actinghorizontally in any direction whereapplicable according to IS 875(Part 3).

Rw2 = loads due to the out of service windacting horizontally in any directionwhere applicable according to IS 875(Part 3).

Rd = loads due to collision with endbuffers.

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d) Loads due to the maximum load that themotor can actually transmit to themechanism while starting, stalling or dueto higher actual power.

7.4 Design Procedure

7.4.1 General

Mechanism components shall be proportionedby checking that they have adequate safetyagainst becoming unserviceable as a result of asingle combination of extreme loadingconditions causing fracture, bending or othertype of failures. They shall also be checkedwhenever appropriate against fatigue,deflection or over heating. In this connection,consideration shall be given to theconsequences of failure. For example, failure inhoisting mechanism component is usually moredangerous occurrences than failure of ahorizontal motion mechanism.7.4.2 Basis of Design

Mechanism components are checked dependingon the ultimate strength by verifying that thecalculated stress does not exceed a permissiblestress dependent on the breaking strength ofthe material used.7.4.3 Permissible Stress

Mechanism component shall be checked forstrength under Case I, II, III and IV loadingconditions and load combinations specifiedin 7.3.2. The value of the permissible stress Fais given by following formula where unit ofstress was defined as N/mm2.

where

7.4.4 Relation between Calculated andPermissible Stresses

According to the type of loading to beconsidered the following relations shall beverified:

a) Pure tension 1.25 ft ≤ Fab) Pure compression fc ≤ Fa

Table 2 Values of Co-efficient, Cdf( Clause 7.4.3 )

c) Pure bending either compression ortension

fbt or fbc ≤ Fa

Fult = ultimate tensile strength of thematerial.

Cdf = duty factor for the appropriatemechanism class. For the valuesrefer Table 2.

Cbf = basic stress factor corresponding toeach case of loading. For the valuesrefer Table 3.

Csf = safety factor depending on thematerial used. For the values referTable 4.

FaFult

Cdf Cbf× Csf×--------------------------------------=

Group Classifi- cation

of Mecha-

nism

For Mecha- nism

Used for Horizontal

Motion

ForMecha-

nism Used for Vertical Motion

For Mechanism Used for Vertical

Motion with People or While

Handling Dangerous for

Example, Molten Metals, Highly

Radio-Active or CorrossiveProducts

M1 1.00 1.18 1.32

M2 1.06 1.25 1.40

M3 1.12 1.32 1.50

M4 1.18 1.40 1.60

M5 1.25 1.50 1.70

M6 1.32 1.60 1.80

M7 1.40 1.60 1.90

M8 1.50 1.70 2.00

Table 3 Values of Co-efficient, Cbf( Clause 7.4.3 )

Case of Loading I II III and IV

Cbf 3.15 2.5 2.0

Table 4 Values of Co-efficient, Csf( Clause 7.4.3 )

For ordinary grey cast iron or for cast orforged components where blow holes orinternal cracks can not be detected.

1.25

For mild steel Fe 310 and Fe 410 1.12

For other materials Fe 44 and Fe 57, etc. 1.00

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d) Combined bending and tension

1.25 ft + fbt ≤ Fa

e) Combined bending and compression

fc + fbc ≤ Fa

f) Pure shear

g) Combined bending, tension and shear

h) Combined bending, compression andshear

where

7.4.5 Checking for Fatigue

7.4.5.1 General

Where it is necessary to check a component forfatigue, recognized techniques available forcalculation of fatigue properties shall be used.The choice of the methods used shall be left tothe manufacturer, however he shall specify theorigin of the methods to be adopted if asked bythe customer.

7.4.5.2 Loading condition

Case I of loading condition as specified in 7.3.2shall be used as the basis for all fatigue checks.

7.4.5.3 Factors affecting fatigue strength

For any component, the magnitude of thefatigue reference stress depends upon thefollowing factors:

a) the total number of stress cycles duringthe service life of the component ‘n’,

b) the type of stress cycles (that is, degree ofstress fluctuation),

c) the quality of the material,

d) the size of the component,

e) the surface finish of the component,

f) the configuration of the individual detailsunder consideration,

g) miscellaneous effects such as the effects ofcorrosion, residual stress, electrolyticplating, metal spraying, etc, where undercertain conditions reduce the permissiblefatigue stress. Annex B gives a method forcalculating the fatigue reference stress( pfr ) which takes account from the factor(a) to (g) above and includes allowancegiving a 90 percent probability of survival.

NOTE — A check for fatigue need not be made in thecases, where experience shows that the ultimatestrength check as per 7.4.3 is sufficient.

7.4.5.4 Stresses

The following characteristics shall bedetermined for each type of fluctuating stress,for example tension, compression, bending orshear; occurring during an appropriate stresscycle in the component detail having regard tothe loading that it will experience:

7.4.5.5 Permissible fatigue stress

The permissible fatigue stress ‘Pf’ for each typeof stress, for example tension, bending or shearis given by:

ft = calculated axial tensile stress,

fc = calculated axial compressive stress,

fbt = calculated maximum tensile stress dueto bending about both principal axes,

fbc = calculated maximum compressivestress due to bending about bothprincipal axes, and

fs = calculated shear stress.

3fs fa≤

1.25 ft fbt+( )2 3 f2+[ ] Fa≤

fc fbc+( )2 3 fs2+[ ] Fa≤

fMax, fMin = extreme values of stressoccurring in the stress cycle.

fMin = considered as negative if it is ofopposite sense to fMax.

pfb = permissible fatigue stress inbending.

pfs = permissible fatigue stress inshear.

pfr = fatigue reference stress atwhich a component detail has a90 percent probability ofsurvival.

fa Max, fa Min= extreme values of axial tensilestress.

fb Max, fb Min= extreme values of stress inbending.

fs Max, fs Min = extreme values of torsionalshear stress.

= maximum degree of stressfluctuation.

fMinfMax------------

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Pf = 0.8 Pfr for hoisting mechanisms

= 0.85 Pfr for all other mechanisms.

Where the component detail is subjected to asingle type of fluctuating stress that is fMaxshall not exceed Pf the permissible fatiguestress.

The stress combination occurring mostfrequently in practice in a component detail isthat of bending and torsion. The detailssubjected to this combination shall be designedso that:

7.4.6 Checking for Crippling

Component subjected to crippling that isoverall flexural buckling due to axialcompression shall be checked so that thecalculated stress does not exceed a limit stressdetermined as a function of critical stress abovewhich there is a risk of crippling occurring. Forthis check co-efficient Cdf, as given in Table 2shall be taken into account.

7.4.7 Checking for Wear

In the case of parts subjected to wear, thespecific physical quantities such as surfacepressure or the circumferential velocity mustbe determined. The figures must be such thaton the basis of present experience they will notlead to excessive wear.

7.4.8 Means of Access

7.4.8.1 General requirements

In front of the panel the working place shall beminimum of 500 mm or width of the door of thepanel or whichever is more. Safe means ofaccess shall be provided to the driver’s cabinand to every place where any person engagedon the inspection, repair and lubrication of thecrane will be called upon to work; adequatehandholds and footholds being provided wherenecessary.

7.4.8.2 Platforms

Every platform shall be securely fenced withdouble tiered guard rails having a minimumheight 1.1 m and toe boards, unless parts of thecrane structure provided safely. The platformnormal width with only check plates shall be ofsufficient to enable normal maintenance workto be carried out safely. On bridge platform,which shall be not less than 0.75 m in normalwidth, the fencing shall extend along the fulllength of the outer edge.

Guard rails on the crab side of the bridgeplatform may be provided, if required.

7.4.8.3 Ladders

Side of ladders normal width with only checkplates preferably from platform to the cabinshall extend to a reasonable distance above theplatforms or other reliable handholds shall beprovided. Ladders shall if possible, slopeforward. Vertical ladders exceeding 3 m inlength shall be provided with back safetyguards.

8 SELECTION OF COMPONENTS

All components shall be selected or designedunder the loading conditions specified in 7.3.

8.1 Lifting Hooks

8.1.1 General

Lifting hooks shall comply with IS 3815 andIS 5749.

8.1.2 Types

For loads up to and including 50 t, Shank typeplain hooks be used unless otherwise specifiedby the purchaser. For loads of 50 t and over,hooks of Rams horn type or triangular liftingeyes are to be preferred where there is a chanceof fouling of hook and the risk of displacementof load during hoisting and for lowering ‘C’ typehook shall be used. Hook with hook latch is tobe provided with closing fingers to preventslippage of load. However an option can begiven to the purchaser on whether hook is to beprovided with closing fingers or hook latch. Inthis case the hinge lug for the closing fingershall be forged with the hook. The finger shallbe capable of taking load equal to 1.5 times ofthe weight of hook block without distortion inaccordance with IS 13870 (Part 1).

8.1.3 Mounting

Swiveling hooks shall be mounted on thrustbearings. A protective skirt shall be provided toenclose the bearings. The thrust bearings shallbe provided with facilities for lubrication,however facilities for lubricating need notnecessary in case of self lubricated nylonbearing pads. If required, a locking device shallbe fitted to prevent rotation of hook.

8.2 Shafts

8.2.1 Material

All shafts shall be made of steel. Shafts andaxles shall have ample strength, rigidity andadequate bearing surfaces. Suitable surfacefinish for stressed portions of the shafts shallbe selected having regard to size, stress levels,severity of stress raising features and the needs

f b MaxP fb

-----------------

2 fs MaxP fs

---------------

21.0<+

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of bearings, seals, etc. Adequate allowancesshall be made for the effective losses in sectiondue to key-ways, splines, etc. Large changes inthe section shall be avoided wherever possible.Shafts, if shouldered, shall be provided withfillets of as large a radius as possible and/or besuitably tapered. All shafts shall be supportedon minimum two bearings. Splines andserrations shall comply with relevant IndianStandards.

The travel driving shaft or shafts shall besupported on self aligning bearings at adistance so that the deflection due to the selfweight of the shaft is between 0.03 to 0.05percent of unsupported length of the shaft.Angular deflection of the line shaft at torquecorresponding to 1.5 times the motor torqueduring acceleration period shall not be morethan 0.25° per metre of shaft length. The drivefor the line shaft shall be mounted as close aspracticable to the centre of the span. Each partof the drive shaft shall be designed to transmitmaximum torque due to the most unfavourableload position.

8.3 Wire Rope

8.3.1 General

Hoisting rope, unless otherwise specified oragreed by the purchaser, shall conform toIS 2266. Steel core ropes with construction andtensile designation of wires as ‘1960’ shall beused for the applications under water or in thecorrosive atmosphere or while handling hotmetal. Ropes working under water and incorrosive atmosphere should be galvanized.

8.3.2 Selection Procedure

The selection procedure adopted here assumesthat the ropes are lubricated correctly, that thewinding diameters on the pulleys and drum areselected in correspondence with this standardand that the ropes are properly maintained,inspected and periodically replaced. Theselection of rope diameter shall be related tothe following:

a) group classification of the mechanism,

b) the rope receiving system employed andits efficiency,

c) rope inclination at the upper extremeposition of the hook, if the rope inclinationwith respect to hoist axis exceeds 22.5°

The minimum breaking load F0 of the ropeintended for a particular duty shall bedetermined from the formula given below,however impact factor should not be consideredwhile calculating the rope tension.

F0 = S × Zp × Cdf

where

8.3.3 Examination, Maintenance and Discard of Wire Ropes

For the examination, maintenance and discardcriteria of wire ropes, guidelines given inIS 3973 shall be adopted.

8.4 Rope Drum

8.4.1 General

Drums shall be designed for single layer ofropes only and shall be designed withmultilayer guided rope when agreed to betweenthe manufacturer and the purchaser.

8.4.2 Length of the Drum

The drum shall be of such length that each leadof wire rope has a minimum of two full turns onthe drum when hook is at its lowest position nottaking into consideration the turns covered bythe wire rope anchorage and one spare groovefor each lead of the wire rope on the drum whenhook is at its highest position.

In the case where the drum flanges are notprovided, a free length not less than 4 times tothe diameter of the wire rope or 100 mm diawhichever is more is to be provided beyond thelast groove center line at the anchorage point.

8.4.3 Flanges

The drums shall be flanged at one or both endsin the following conditions such as:

a) For single flange drum, at the end wherewire rope is released.

b) For drums having handed grooves at bothends if wire ropes are released from theend of drums.

c) For multi-layer wire ropes at both ends.

d) If required by the purchaser.

S = maximum rope tension consideringinclination of the rope in theuppermost position.

Zp = minimum practical coefficient ofutilization. For normal condition Zpshall be taken equal to 3.5 for M1 toM8 other than hot mill duty cranes. Zpshall be taken equal to 5 for hot millduty cranes.

Cdf = duty factor for hoisting as definedin 7.4.3.

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Where provided, the flanges shall project abovethe wire rope to a distance not less than 2 timesof the wire rope diameter.

8.4.4 Lead Angle

The lead angle of the rope shall not exceed 5° oneither side of helix angle of the groove in thedrum.

8.4.5 Grooving of the Drum

Rope drums shall have machined grooves andthe contour at the bottom of the grooves shallbe circular over a minimum angle of 120°.

Grooving shall be finished smooth and shall befree from surface defects likely to injure thewire rope. The edges between the grooves shallbe rounded. The radius of the groove shall bebetween 0.53 to 0.59 times the diameter of thewire rope rounded off upwards to the nearest0.5 mm. The depth of the groove shall not beless than 0.3 times the diameter of the wireropes for drum with single layer of the wirerope and 0.2 times the diameter of the wirerope for multiple layers of wire rope on thedrum. The pitch of the grooves of the drumshall not be less than 1.08 times the diameter ofthe wire rope for the drum with single layer ofthe wire rope and 1.05 times the diameter ofthe wire rope for multiple layers of the wirerope on the drum.

8.4.6 Diameter of the Drum

The diameter of the drums at the bottom of thegroove shall be standardized to sizes 200, 250,315, 400, 500, 630, 710, 800, 900, 1 000 and1 250 mm.

The diameter of the drum measured at thebottom of the groove shall be not less than thevalue calculated as follows:

Dd = 12 × d × Cdf × Crc

where

For wire rope construction:

8.4.7 Material for the Drum

Drums shall be made of seamless pipe as perASTM A 106 GR A and B, cast iron of minimumGrade 25, cast steel, rolled steel of weldedconstruction and in case of welded drum thisshould be stress relieved.

8.4.8 Strength of the Drum

Drums shall be designed to withstand thecompressive stress caused by the wound of wirerope, bending stress due to beam action andtorsional stress.

8.4.9 Rope Anchorage

The end of the wire rope shall be anchored tothe drum in such a way that the anchorage isreadily accessible. Each wire rope shall havenot less than two full turns on the drums whenthe hook is at the lowest position not takinginto consideration the turns covered by the wirerope anchorage.

8.5 Sheaves

8.5.1 Grooving

Sheave shall have machined groove. Thecontour at the bottom of the groove shall becircular over a minimum angle of 120° andshall have an included angle of 50°. The groovesshall be finished smooth and shall be free fromsurface defects likely to injure the wire rope.The depth of the groove shall not be less than1.5 times the diameter of the rope. The radiusof the groove shall be between 0.53 to 0.59times the diameter of the wire rope rounded ofupwards to the nearest 0.5 mm.

8.5.2 Diameter of the Sheave

The diameter of the sheave measured at thebottom of the groove shall not be less than thatat the drums specified in 8.4.6. The diameter ofthe bottom of the groove at an equalizingsheave shall not be less than 62 percent at theminimum sheave diameter. The value iscalculated as follows:

Ds = 12 × d × Cdf × Crc × Crr

Ds = 8 × d × Cdf × Crc for equalizing sheave.

where

Dd = diameter of the drum measured at thebottom of the groove, in mm;

d = diameter of the rope, in mm;

Cdf = duty factor for hoisting for theappropriate mechanism class asdefined in 7.4.3; and

Crc = factor dependent on the constructionof wire rope.

6 × 36 or 6 × 37

6 × 24

6 × 19

Crc = 1.0,

Crc = 1.12,

Crc = 1.25.

Ds = diameter of the sheave measured atthe bottom of the groove in mm,

d = diameter of the rope,

Cdf = duty factor for the appropriatemechanism class as defined in 7.4.3.for hoisting,

Crc = factor dependent on the construction

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For sheaves the value of the co-efficient Crrdepends upon the number of pulleys in thereeving and the number of reverse bends.

Taking the values of

The corresponding values of the co-efficient ‘Crr’are given in Table 5.

8.5.3 Lead Angle

The angle between the wire rope and a plainperpendicular to the axis of the pulley shall notexceed 5°.

8.5.4 Material

Sheaves shall be manufactured from cast steel,or forged steel or rolled steel or from suitablegrades of nylon.

8.5.5 Sheave Guards

Sheaves shall be provided with rigid guards toretain the wire ropes in the grooves. Theguards shall fit close to the flange having aclearance not more than one-fourth of thediameter of the wire rope between the sheaveand the inside of the guard. Bottom blocksheaves shall be enclosed except for wire ropeopenings.

8.6 Track Wheels

8.6.1 General

Track wheels shall have cylindrical or tapered

(conical) treads. With flanges or with the helpof horizontal guide rollers they shall guide thecrab or the crane effectively to preventderailment. The wheels shall be mounted insuch a manner as to facilitate removal andreplacement. This clause gives criteria fordetermining the size of the wheels required tomeet a particular duty. It is assumed here thatthe rail track is maintained in good conditionand that the wheels are correctly aligned.

8.6.2 Design Factors

The factors those need to be considered whendetermining the required material anddiameter for rail wheels are as follows when:

a) load on the wheel,

b) type and the material of the rail,

c) speed of rotation of the wheel ( n ),

d) length of travel ( L ) on the rail andnumber of load carrying wheels ( Z )operating on the same length of rail, and

e) group classification of the mechanism.

8.6.3 Wheel Hardness

The minimum hardness of the wheel rimshould be maintained 300 to 350 BHN withminimum depth of 10 mm. The formula fordetermination of wheel hardness is as follows :

where

8.6.4 Material

The material for the track wheels should be ofC-55 MN 75 and also can be of steel or cast orwrought or shall have steel tyre shrunk on andregistered with minimum hardness as obtainedearlier. The steel shall not contain more than0.06 percent either of sulphur or phosphorus.

of the rope as defined in 8.4.6, and

Crr = co-efficient depending upon the type ofreceiving system.

Nb = 1 for a drum,

Nb = 2 for a pulley carrying the rope in thesame direction of wrap (no reversebend),

Nb = 3 for a pulley carrying the rope in thereverse direction of wrap (reversebend),

Nb = 0 for compensating pulley, and

Nt = is the sum of these values of Nb for thegiven rope reeving.

Table 5 Values of Coefficient Crr

Nt < 5 6 to 9 ≥ 10

Crr 1 1.12 1.25

BHw = Brinnel hardness of the wheel rim;

BHr = Brinnel hardness of the rail;

CL = factor dependent on the rail length ‘L’used by ‘Z’ number of wheels. Forvalues refer Table 6;

Cz = factor dependent on the number ofload carrying wheels ‘Z’ For valuesrefer Table 7; and ( see Fig. 4 and 5 )

Cd = factor dependent on the wheeldiameter ‘D’ For values refer Table 8.

BHw1.3 BHr× CL×

Cz Cd×----------------------------------------=

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For light duty cranes, cast iron wheels shouldbe prohibited.

8.6.5 Loading Conditions

In assessing the individual loadings arisingunder Case I and Case II loading conditions,the hook load impact factor is not applied.

8.6.6 Diameter of Wheels

The tread diameter of wheels shall bestandardized to sizes 160, 200, 250, 315, 400,500, 630, 710, 800, 900, 1 000 and 1 250 mm.The use of wheels of diameter greater than1 250 mm is not recommended. The minimumtread diameter of the wheel may be calculatedfrom either of the formulae given below:

Table 8 Values of Co-efficient Cd( Clause 8.6.3 )

where

For a rail with a total width ‘B’ having roundedcorners of radius r at each side and having:

a) Flat bearing surface a = B – 2 r

Table 6 Values of Co-efficient CL( Clause 8.6.3 )

Lengthm

CL

10 1.00

16 1.05

20 1.08

25 1.11

31.5 1.14

40 1.17

50 1.20

63 1.23

80 1.26

100 1.29

Table 7 Values of Co-efficient CZ( Clause 8.6.3 )

Z in Nos.m

CZ

2 1.00

4 1.08

6 1.13

8 1.17

10 1.20

12 1.22

14 1.24

16 1.26

Diametermm

Cd

160 1.00

200 1.03

250 1.06

315 1.09

400 1.12

500 1.15

630 1.18

710 1.21

800 1.21

900 1.24

1 000 1.24

1 250 1.27

D = tread diameter of the wheel in mm;

Pmean = mean wheel load in newtons;

A = useful width of rail;

Cdf = duty factor for the appropriatemechanism class as defined in 7.4.3;

Cbh = hardness factor for the wheelmaterial. For values, refer Table 9.Here wheel hardness Bhw ascalculated in 8.6.3 shall be used evenif wheel rim if hardened more forlonger wheel life;

Csf = safety factor depending on thematerial used as defined in 7.4.3;and

Csp = co-efficient depending on the speed ofrotation of the wheel as defined inTable 10.

DPmean Cdf× Csf×1.5 a Cbh× Csp×----------------------------------------------=

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FIG. 4 SIZE FACTOR, CZ

FIG. 5 SIZE FACTOR, CZ

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b) Convex bearing surface

where

8.6.7 Determination of the Maximum StaticWheel Loading ‘Ps’

Where this shall be the maximum wheel loadoccurring with the wheel static upon the rail inany of the four cases of loading.

8.6.8 Determination of the Mean Wheel Loading

For loading conditions of ‘normal servicewithout wind’ and ‘normal service with wind’ amean wheel load shall be determined from therelationship by the formula given below:

where

8.6.9 Flanges

The dimension of flanges for guiding trackwheels at the base shall not be less than thevalues given in Table 11.

Table 9 Co-efficient Cbh( Clause 8.6.6 )

Bhw Fult Cbh

125 415 1.00

140 470 1.40

160 540 1.90

180 605 2.50

200 680 3.15

224 760 4.05

250 845 5.30

280 950 6.70

315 1 065 8.65

355 1 200 11.20

400 1 355 14.50

450 1 530 18.70

500 1 725 23.20

560 1 950 29.50

B = width of the rail, and

r = radius of the rounded corners of theside.

PMax = maximum wheel load, and

PMin = minimum wheel load.

a B 4 r3

--------–=

Pmean2PMax PMin+

3-------------------------------------=

Table 10 Values of Co-efficient Csp( Clause 8.6.6 )

Rotation Speedrpm

Csp

200 0.66

160 0.72

125 0.77

112 0.79

100 0.82

90 0.84

80 0.87

71 0.89

63 0.91

56 0.92

50 0.94

45 0.96

40 0.97

35.5 0.99

31.5 1.00

28.0 1.02

25.0 1.03

22.4 1.04

20.0 1.06

18.0 1.07

16.0 1.09

14.0 1.10

12.5 1.11

11.2 1.12

10.0 1.13

8.0 1.14

6.3 1.15

5.6 1.16

5.0 1.17

Table 11 Minimum Flange Dimensions( Clause 8.6.9 )

All dimensions in millimetres.

Diameter of Wheels

Depth of Flange Thickness of Flange

160, 200, 250, 16 16

315, 400, 500 20 20

630, 710, 800, 900, 1 000

25 25

1 250 30 30

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8.6.10 The flanges shall be adequately taperedto prevent it from rubbing on the rails. Fillets ofradius 0.7 to 0.9 r shall be provided (where r isthe radius of rail corners).

8.6.11 Width of Tread

The width of the wheel tread shall be greaterthan the rail head by an amount which shallsuitably allow for the variations in the gantryrail alignment, gantry track span dimensionsand crane span dimensions.

8.6.12 Adhesion of the Drive Wheels

To eliminate slipping of the drive wheels of thetravelling mechanism of the crane or crab, thedesign shall be checked for adhesion under themost unfavourable combination of loadsproducing maximum and minimum loads onthe drive wheels. The co-efficient of adhesion(friction) shall be taken as 0.15 for dry rails and0.1 for damp rails.

8.7 Bearings

8.7.1 General

Bearing pedestals and mounting shall becapable of transmitting the load from thebearing to the supporting structure. Suitableprovision shall be made for those cases wherethe resultant load is not acting as acompression load on a bed plate. Suitableanti-friction bearings shall be used for live orfixed axles for wheels, for the shafts used forsheaves and drums and for the shaftssupporting gears.

Suitable bushing as used in bogies and bushbearings made out of phosphor bronze, cast ironor nylon can be used for hinges or balances ofcrane bridge or trolley, cross beams for hooks,magnet suspension, links for grab bucket andat places where rotation is not powered.

8.7.2 Anti-Friction Bearings

Anti-friction bearings shall be installed andfitted in accordance with the manufacturer’sprocedures with adequate provision forlubrication.

Arrangements for axial location shall be inaccordance with correct practice so thatunforeseen additional bearing loads are notintroduced. Bearings shall be capable ofwithstanding the greatest static and ordynamic load it can be subjected to underwhichever of the loading cases is the mostunfavourable. The bearings shall haveminimum static load capacity Fsb for aparticular duty as given below:

Fsb = P × Cdf

where

8.7.3 Plain Bearings

The selection, fitting, lubrication, the pressureand rubbing velocity shall be in accordancewith the recommended practice and serviceexperience for the material involved havingregard to the nature of the loads and operatingconditions. Plain bearings shall, wherepracticable, be of the adjustable cap type. IfPhosphour Bronze bearings are used thepressure shall not exceed 6.86 MPa, whereinMPa is the unit of pressure.

8.7.4 Lubrication

Provision shall be made for the servicelubrication of all the bearings unless sealed andlubricated for life. Ball and roller bearingsshall, in addition, be suitably lubricated beforeassembly.

8.8 Gearing

8.8.1 General

All gears shall be machine cut hardened andprofile ground and shall confirm to relevantIndian Standards. However the Crane gearingscan be designed or selected on the basis of theconditions given below:

a) service experience under conditionscorresponding to the classificationparameters involved, or

b) other recognized standards or codes whichhave been proved satisfactory in craneservice, or

c) any other method for making calculationswhere manufacturer must indicate originof the method adopted if asked by thepurchaser.

The gearing shall be designed for a service lifecompatible with the service life of themechanism, the class of utilization and state ofloading used for the mechanism, and havingregard to the prime mover and brake.

P = maximum static load on the bearingunder any load condition and for theequivalent load to be determined asspecified by the manufacturer.

Cdf = duty factor as defined in 7.4.3. Life ofthe anti-friction bearings shall becalculated in accordance with themanufacturer’s recommendations andbased on working hours specified forthe duty of the mechanism.

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8.8.2 Material

All gears shall be of cast or wrought steel orforged from low/medium carbon alloy steel andsuitably heat treated.8.8.3 Gear Boxes

All pair of gear boxes shall be so except forplanetary gear boxes either spur or helical andgears shall be automatically oil lubricateddesigned that the first pair of gears shallalways be helical and gears shall beautomatically oil lubricated. The gears shall bereadily removable and the boxes shall be oiltight. They shall be of rigid construction andfitted with inspection covers and lifting lugswhere necessary. The inspection covers shall beso positioned that the first and second pinionshafts can be inspected. Minimum andmaximum oil level indicators and facilities foroil filling, oil drainage and air breathing shallbe provided.

All gear boxes shall be in totally enclosedconstruction. Teeth shall be machine cut,suitably hardened and tempered and shallconform to AGMA or IS 4460. The surfacehardness of pinion shall be between 266 to 300BHN and that for gear shall be between 217 to255 BHN. Difference of hardness of pinion andgear must not be less than 20 BHN.

The gear box mounting shall be machine cut,seated and positively located on machinedsurface.

Material of the gear box shall be cast, wroughtor forged from low/medium carbon alloy steeland suitably heat treated. The fabricated gearboxes shall be stress relieved before machining.The internal surfaces of the gear box shall bepainted with oil resisting paint.

8.9 Couplings

All couplings shall be of cast, wrought or fromforged steel, tooth portion to be heat treated tohardness HB 241-280 and also shall bedesigned to suit the maximum torque that maybe developed. Solid and flexible couplings shallbe aligned with the same accuracy so that theymatch accurately.

Hoist drums shall be connected to gear boxoutput shaft by means of flexible drumcouplings or barrel couplings to cater formisalignment, frame distortions, etc, and alsoto facilitate removal of hoist drum. Shaftcouplings shall be as near as practicable to thebearings.

8.10 Fasteners

8.10.1 Keys

Keys and key-ways shall conform to relevant

Indian Standards. Keys shall be so fitted andsecured that they can not work loose in service.

8.10.2 Bolts, Nuts, Screws and Washers

All bolts, screws and set screws in rotatingparts shall be locked. All other bolts and screwsshall be fitted and locked if required by thepurchaser so that they do not get loose. Bolts intension shall be avoided wherever possible. Allbolts, screws, nuts shall be made out of hightensile alloy steel material and shall be inaccordance with relevant Indian Standards.Black bolts shall not be used. All bolts and nutsshall be easily accessible.

Tapered washers and tapered pads when usedshall be tack welded in place. All washers shallconform to IS 1364 and IS 1367 respectively.

8.11 Buffers

8.11.1 General

Suitable buffers shall be fitted to each end ofthe end carriage assemblies and on both sidesof crab or the bridge.

Buffers shall be so mounted to permit easyremoval of wheels. Limit switches shall beprovided in such a way that drive motors areswitched off before the buffers are pressed.Buffers will be provided between the cranes ifmore than one crane is running on the sametrack.

8.11.2 Type of Buffers

Spring buffers, hydraulic buffers and buffersmade out of resilient plastic, rubber orpolyurethane may be used. Wooden buffersshall not be used. Buffers shall have sufficientenergy absorbing capacity to bring the loadedcrane or crab to rest from a speed 50 percent ofthe rated speed at a deceleration rate notexceeding 5 m/s2.

8.12 Braking

8.12.1 General

a) The parts used for braking shall be madefrom hard wearing material withadequate thermal capacity for the dutyrequired. Due allowance shall be kept forthe brake drum capacity to dissipate heatgenerated due to frequent braking. Therubbing surface shall be smooth and freefrom defects. The brake lining shall beprotected from water, grease, oil or otheradverse effects.

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b) The bearing pressure on the linings shallbe conducive to uniform braking and longlife. Brakes shall be provided with meansof adjustment to compensate for wear.

c) All electro-mechanical or electro-hydraulicbrakes shall be applied automatically bysprings or weights when the power supplyto the brake is interrupted or when thecircuit breaker is opened or when thecontroller is brought to off position. Powerapplied brakes shall not be fitted withouta back up system of power released typeand without prior approval of thepurchaser.

d) Springs of electro-mechanical brakes shallbe of the compression type and shall notbe stressed in excess of 80 percent of theelastic limit of the material. Brakeweights if provided shall be securelybolted to the levers and locked.

e) Under service conditions brakes appliedby hand shall not require a force greaterthan 120 N (12 kgf) at the handle. Brakesapplied by foot shall not require a force ofmore than 200 N (20 kgf) on the pedal.The stroke of hand levers shall not exceed300 mm and of pedals 150 mm. Lockingdevices shall be provided on brake leverswhere necessary. Brake pedals shall havenon slip surface.

f) Electro-hydraulic thruster operatedbrakes are permissible on all motions.

g) Appropriate mechanical, electro-hydraulicbrake magnet or any other alternativebrake releasing gear may be used.

8.12.2 Braking Path

The braking path of the crane motions shall bewithin the distance as calculated from thefollowing formula with all the brakes appliedsimultaneously unless required otherwise bythe purchaser:

where

8.12.3 Hoist Motion Brake

All electrically operated hoisting motion shallbe fitted with an electro-hydraulic/electro-magnetic fail safe brake. The brake will arrestthe motion and hold at rest any load up to andincluding overload test load at any position ofthe lift.

The provision shall be made to enable any loadcapable of over coming the friction in thesystem up to and including the test load to belowered safely in a controlled manner in theevent of power failure. The brake shall bedesigned to exert a restraining torque ofminimum 50 percent greater than themaximum torque transmitted to the brake fromthe suspended load under the loadingconditions as specified in 7.3. In estimating thistorque the effects of friction in the transmissionsystem between the load and the brake shall beignored.

Cranes handling dangerous liquids be fittedwith an independent delayed action typeadditional brake on the hoisting motion. Eachof these two brakes shall have minimumbraking torque of 125 percent of the computedfull load torque.

Total torque of the externally applied brakes,acting simultaneously, shall not be more thanthe total pull out torque of the motors.

8.12.4 Travelling Motion

Every electrically operated travelling motionshall be fitted with a mechanical or hydraulicbrake or an automatic electro-magnetic/electro-hydraulic brake or a combination of thetwo, if required. The brake shall be capable ofbringing a fully loaded crane to rest with leastpossible shock from the highest speed it canattain with electro-magnetic/electro-hydraulicbrakes, limit switches shall be provided in thismotion.

The travelling motion of every electric outdoorcrane shall be provided with the automaticelectromagnetic/electro-hydraulic parkingbrakes if the service brake is not ofelectro-mechanical type. All overhead cranesworking outdoors shall be provided with anadditional storm brake for anchoring it when itis left unattended or under the storm condition.Gantry cranes working outdoors with rails onground shall be provided with rail clamps orscrews jack or chain anchor at each corner foranchoring it during the storm.

The braking torque shall not be less than thefull load torque transmitted to the brake andshall not be more than the pullout torque of themotor.

S = braking path in metres,

V = speed of motion in metres/minute,

Cdf = co-efficient for group classification andtype of motion as defined in 7.4.3, and

Cb = 80 for hoisting motions,

= 20 for travel motions.

S VCb Cdf×----------------------=

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8.12.5 Traversing Motion

The cross traverse motion should alsonecessarily be provided with brake/brakes asspecified for long travel motion. Whenelectro-mechanical brakes are provided, endlimit switches shall be provided in this motion.

The cross traverse motion brake(s) shall becapable of bringing the fully loaded crab to restwith least possible shock from highest speed itcan attain.

The braking torque shall not be less than thefull load torque transmitted to the brake andshall not be more than the pullout torque of themotor.

9 GUARDING AND WEATHER PROTECTION

9.1 Guards

All gears, wheels, pinions and chain drivesshall be totally encased by the guard or by thestructure of the crane, so as to be safe as ifcomplete encasement is provided. Effectiveguards shall be provided for all revolving shaftsand couplings rotating at high speeds or havingprotruding parts or are so situated in relationto the structure of the crane as to be safe as ifguards were provided. The sheaves of the hookblock shall be guarded to prevent the possibilityof trapping between a sheave and thein-running wire rope.

Suitable guards shall be provided on thedown-shop lead side to prevent accidentalcontact between wire ropes or hook block orlifting attachments and live conductors. It isalso suggested that all guards and protectiveequipment shall be painted in ‘Golden Yellow’or as in confirmation to relevant IndianStandards. This is required to identify aboutthe location of the guards and protectiveequipment in the crane easily for thereplacement of the guards/protectiveequipment while commissioning or while thecrane is taken up for maintenance work.

9.2 Weather Protection

For outdoor crane all electrical and mechanicalequipments shall be adequately protected fromthe weather. All weatherproof covers shall beeasily removable.

9.3 Painting

Before dispatch of the crane, the completecrane covering structural, mechanical andelectrical parts shall be thoroughly cleaned ofall dirt, grease, scale and rust by shot blastingor chemical cleaning methods. A single coat ofprimer shall be given to all parts exposed to theweathering effects and if are not already

treated earlier or effectively lubricated. At leasttwo additional finishing coats of paint forindoor cranes/outdoor cranes of colour ofcustomer’s choice shall be given on all primerpainted surfaces.

All moving parts up to the height of 5.0 m fromworking level or ground shall be painted in‘Golden Yellow’ colour. The bright exposedparts of the crane shall be given one coat of rustinhibitor. Interior of all gear boxes shall bepainted with one coat of oil resisting paint.Areas that are inaccessible after assembly orerection shall be treated before assembly orerection.

Where the cranes are supplied for use inabnormal working conditions special protectionmay be necessary.

Any additional requirements regardingpainting shall be as agreed between thepurchaser and the manufacturer.

10 LUBRICATION

Provision shall be made for lubricating allbearings unless sealed or lubricated for life,matting gears and chain and sprocketsarrangements. Where necessary easy accessshall be provided.

In case centralized lubrication system is askedby the purchaser, provision shall be made atthe bearings to vent the lubricant pressure.

Lubricating nipples, pipes, and adopters shallgenerally comply with the relevant IndianStandards.

A lubricating chart shall be provided indicatingall the lubricating points with ‘Red colour’paint, the type of lubricant and recommendedfrequency of lubrication.

11 MOTION LIMITING DEVICES

11.1 Hoisting Limiting Devices

Positively operated hoisting motion limitingdevices shall be provided that stops the upwardand downward motion when predeterminedlevel is reached to prevent over winding or overunwinding.

NOTE — The limiting device shall be regarded as asafety feature and not as a routine operational means ofstopping. Where normal operation of the cranenecessitates frequent approach to the upward limit, anadditional motion limiting device shall be provided thatoperates independently and requires manual resetting.

11.2 Cross Traverse and Long Travel Limiting Devices

Limiting devices shall prevent the followingconditions:

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a) over traversing and over travelling, and

b) collusion where two or more crane/trolleysoperating on the same track.

11.3 Load Indication and Load Limiting Devices

Load indication and limiting devices arerecommended if weights of objects to be liftedare not known accurately. When fitted, theyshall sense the load on the crane by meansother than the current consumed by the hoistmotor. If the load lifted is more than S.W.L.load limiting devices shall stop further hoistingoperation till the load is removed or reduced.

11.4 Drawings and Documents

Following drawings and documents shall besubmitted for approval of the purchaser beforemanufacturing of the crane:

a) GA drawing of the crane;

b) GA drawing of crab/trolley;

c) GA drawing of individual mechanisms;

d) Drawing of bridge, end girder and theirconnection;

e) Sub-assembly drawing for wheels, hookblocks and hoist drums;

f) Calculations for selection of motor,reducer, brake, couplings, etc; and

g) Calculation for bridge girder end carriageand their connections.

SECTION 3 ELECTRICAL

12 MOTORS

12.1 General

The motors shall be selected to take care ofloading conditions as given in 7.3.2 and to suitthe duty of the mechanism in which it is used.The motors shall be suitable for frequentreversing, frequent acceleration and braking.

12.2 Selection of Motor Sizes

When the duty cycle can be adequatelyassessed, d.c. or a.c. motors for any cranemotion may be selected so that the motortemperature in actual service shall not exceedthe permissible limits specified in IS 325 forthree phase induction motors or other relevantIndian Standards ( see Annex F ), taking into

account the class of insulation adopted and theambient temperature at the crane location.When duty cycle can not be assessed therecommended assumptions and designproceedings are set out in Annex C for theselection of motors to suit duty cycles andnormal service conditions.

dc Motors shall be series wound and ac motorsshall be squirrel cage or slipring induction typeunless specified otherwise. The dc motorsshould be selected in agreement with theirmanufacturer’s. It is necessary to know thetorques, the power calculated and the trueoperating conditions of the motor.

NOTES

1 Motor power as computed in Annex C has beenmultiplied by service factor to make the motorthermally capable for the duty condition. Whiledesigning controls, the crane manufacturer should usecomputed motor-power without service factor forselection of components. The components selectedshould be able to carry the full load current of the motorpower computed without service factor at the specifiedduty cycle and ambient temperature of operation of thecrane.

2 If specially required by the purchaser, the drive motorshould be protected against over heating by means ofthermistors embedded in the motor windings. Matchingthermistor trip relay should be provided in the controlpanel.

12.3 Enclosures

All crane motors shall be totally enclosed withor without fan cooling arrangement and shallconform to IS 325, IS 1231 or IS 2223 asappropriate. The enclosures shall suit thespecified service conditions and shall bestipulated with the enquiry or order. If notspecified by the purchaser the motor enclosureshall be minimum IP 44 for indoor applicationsand IP 55 for outdoor applications of ac motorsand IP 23 for dc motors. For outdoorapplications separate canopy shall be providedfor motors.

12.4 Torque Rating

The motor shall be capable of producingmaximum torque required to produce motion inthe most unfavourable loading condition. Thepull out torque of the motor at rated voltageand frequency should not be less than 2.0 timesthe rated torque for the all mechanism classesfrom M1 to M8 as corresponding to computedmotor power without service factor.

12.5 Limiting Speed

Motors shall be capable of withstanding amaximum speed of 2.5 times rated speed or2 000 rev/min, whichever is less.

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12.6 Insulation

The motor shall be of Class B insulation orbetter as classified in the relevant IndianStandard specifications.

12.7 Accessibility

Motors shall be so located that the brushes,gear and terminals are accessible for inspectionand maintenance.

12.8 Terminals

Motor leads shall be brought out from themotor frame to terminals in the terminal boxfixed to the motor frame and shall be marked inaccordance with IS 4728.

12.9 Sliprings

Slipring motors shall have continuously ratedsliprings amply dimensioned to give a longtrouble free life.

12.10 ac Motors may be supplied in IEC framesand dc motors in AISSE frames.

12.11 Higher frame size such as above 280 acmotors should have bar wound rotor.

13 ELECTRIC BRAKING (ELECTRO-DYNAMIC BRAKING)

13.1 General

Electro-mechanical braking is referred to anautomatic electric brake whose action is purelymechanical and the braking effect is nullifiedelectrically by a solenoid, or electro-magnet, orelectro-hydraulic release gear. In electricbraking the energy is either returned to theline or dissipated in resistors. In addition to thespecific requirements of this code for the brakesand irrespective of the supply current,electrical braking is permissible on all motionsof electrically operated cranes.

When electrical braking is used, provision shallbe made to limit the current on reversal to asafe value. Effective means shall be providedfor stopping the motion in the event of a powerfailure and in the case of an emergency.

Shunt brakes shall be so connected that it willbe applied when the main circuit-breakingdevice is open irrespective of the position of thecontroller. If required by the purchaser, eachcontrol circuit shall be electrically inter lockedwith all associated shunt breaks to preventpower being applied to the motion when thebrakes are not energized.

NOTES

1 If a hoist is potentiometer controlled, an auxiliary pole

is required on the main circuit-breaker to open theshunt brake and control circuits.

2 In case of hoist motors, either the brakes are releasedwith the energization of motors or the motors areenergized.

13.2 Brake Magnets

The terminals of brake magnets shall beprotected from accidental contact. Theconnections and windings shall be effectivelyprotected from mechanical damage. Wherenecessary, magnets shall be provided with anefficient cushioning device. Ratings of brakemagnets and thruster brake motor shall be asgiven in Table 12.

NOTES

1 CDF means ‘Cycle Duration Factor’.

2 The temperature rise of the brake electro-magnet orthruster at any of the specified duty mentioned aboveshall not exceed permissible limits for the particularclass of insulation used with due consideration ofswitching current in rush (due to field forcing in case ofdc magnet).

3 Maximum duration of cycle shall not exceed 10 min incase of intermittent duty. The brake magnets shalloperate at the currents and voltages given in Table 13.

4 Arrangements shall be made, where necessary, toprevent the brake magnet from being energized by theback ‘emf’ of the motor when the supply has beeninterrupted.

14 CRANE CONTROLLING ARRANGEMENTS

14.1 General

The type of controls to be used shall be asagreed between the manufacturer and thepurchaser. Cranes having alternative control orbrake circuit facilities shall be provided with

Table 12 Rating of Brake Electro-magnets and Truster Brake Motor

Type of Actuating Device

Rating

Duty in Percent CDF

Permissible Switching

dc Magnets 204060

100

720

ac Magnets 2040 120

ac Magnets 60100 240

ac Thruster brake motor

60100 720

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means to prevent operation from more than onefacility at any one time.

NOTE — Main circuits are those which carry mainmotor or magnet current. Control circuits with brakecircuit mechanism are those which are used for controlequipment for main motor or magnet.

14.2 Controllers

Controllers shall be rated to comply with therelevant Indian Standard specifications.Controllers shall be adequately protected toprevent accidental contacts with the live parts.Controllers in ‘off’ position shall open all supplylines of the respective motors, unless otherwiseagreed to, in which case a warning notice shallbe fixed to the controllers. On or adjacent toeach control device, there shall be a durablemarking identifying the motion controlled andthe direction of movement.

14.2.1 Control Equipment for dc Motors

Contactors, switches and allied electricalcomponents shall be selected on the basis ofcalculated power in (kW) of the motor.

14.2.2 Control Equipment for ac Motors

The selection of contactors shall be made on thebasis of S 3 – 40 percent rating arrived afterapplying appropriate service factor to thecomputed power of the motor. The rating of thecontrol gears such as switches, overloads, etc,shall be selected according to the computedmotor power without the service factor of themotion served and not on the motor powercomputed by the thermal requirements.

The contactors selected under 14.2.1 and 14.2.2shall have the stipulated contact life as may bespecified by the user.

14.3 Controllers Provided in the Cabin

14.3.1 General

All control handles and pedals shall be placedin convenient position to allow the driver ampleroom for operation and permit an unrestrictedview of the load. They shall be so disposed thatthe contacts and terminal arrangements arereadily accessible for inspection andmaintenance purposes.

14.3.2 Marking Direction of Operation of Controllers

Where practicable controller handles shallmove in the direction of resultant loadmovement. Each controller shall be marked ina permanent manner to show the motioncontrolled and direction of movement. Forvertical lever handle operating hoistcontrollers, movement towards operator shallindicate hoisting and movement away fromoperator shall indicate lowering.

14.3.3 Notching

The notching for the controller handle in the‘off’ position shall be more positive than thenotching in other positions. The handle may beprovided with a lock, latch, dead man or springreturn feature if specifically requested by thecustomer. The control lever shall be providedwith stops and/or catches to ensure safety andfacility of operation. A controller drum fittedwith a star wheel shall be regarded ascomplying with the requirement.

14.3.4 Master Controller

Master controller operated cranes shall beprovided with automatic control of acceleration.Accelerating torque/current peak shall belimited during controller handle movementfrom one notch to the other with dueconsideration to the pullout torque of the motor

Table 13 Brake Magnet Operating Currents and Voltages

( Clause 13.2 )

Windings dcMagnets

acMagnets

For series resistorcontrol

Lift at 60percent rated

current

—

Series Hold at 15percent rated

current

—

Potentiometer control

Lift at 40percent rated

current

—

Hold at 15percent rated

current

—

Shunt *Lift at 85percent rated

voltage

*Lift at 85 percent rated

voltage

*Hold at 50 percent rated

voltage

*Hold at 50 percent rated

voltage

*This is intended to apply with hot coils correspondingto the duty cycle at rated voltages. The temperaturerise of the brake magnet shall not exceed that allowedfor the control equipment fitted.

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and number of rotor accelerating contactorsshall be selected accordingly. For mastercontrol operated cranes the control voltagepreferably 110 ac and shall not exceed 240 V forac or dc supply.

14.4 Pendant Controllers

14.4.1 General

Cranes with pendant controls shall not havelong travel speed in excess of 40 m/min.Pendant control may either descend from thecrab or from the independently travellingtrolley or from a convenient position on thecrane bridge.

14.4.2 Pendant Switches

The pendant switches shall be capable ofwithstanding rough handling without beingdamaged and the cover shall be effectivelysecured. If control is from the floor, theelectrical control circuit to the pendant shall beenergized at not more than 110 V dc or acsupply.

14.4.3 Pendant Control

On all pendant controlled cranes means shallbe provided to prevent inadvertent operationfrom the floor while maintenance work is beingcarried out on the crane. An isolator fitted onthe crane bridge, which can not be operatedfrom the floor will comply with thisrequirement.

14.4.4 Pendant Control Station

If the control is by push buttons or switches,they shall automatically return to the ‘off’position immediately after they are released.One lockable type push button shall beprovided to switch off control power when thecrane is not in use and if other means ofswitching off is not available.

14.4.5 Suspension of Pendant Switch

The weight of the pendant shall be supportedindependently of the electric cables by means ofchain or wire rope. If the pendant enclosure isof metal it shall be effectively earthed. A chainor hook does not provide effective earthconnection.

14.5 Radio Control System

14.5.1 Main features of radio control systemconsist of:

a) A portable transmitter,

b) An antenna and receiver on the bridge,and

c) An intermediate relay panel on the bridgeto amplify the signals for the cranecontactors.

14.5.2 Radiocontrols should be designed so thatif the control signal for any crane motionbecomes ineffective, that crane motion willstop, and conversely signals received from anysource other than the transmitter will notresult in operation of any motion of the crane.The crane must not take off on its own orrespond to or generate false commands. In caseelectricity failure occurs, the crane must stop.

A key switch or equivalent security device onthe transmitter that can be used to preventunauthorised use of the transmitter.

The sending of a continuous or continuouslyrepeating secure signal when transmitter is inuse, which the crane receiver can identify. Asecure signal includes at least threecharacteristics separately recognizable by thereceiver.

An emergency stop device shall be used foremergency stop.

A carrying harness, belt, shoulder strap orlanyard on the transmitter.

14.5.3 The arrangement of the operating leverson the radio transmitter should conform toFig 2A. The manufacturers should supplymotion switches with different shaped knobs sothat the motion can be selected by feel and theoperator’s vision remain on the load. Modularconstruction shall be preferable for easyreplacement.

14.5.4 Typical frequencies used for radiocontrols are in between 450-470 MH for whichlicence is required. The recommended cranecontrols for operating are of maximum 250metre range.

Radio crane control transmitter leverarrangement are of four motions, namely, aregiven below:

Radio crane control transmitter leverarrangement are of three motions, namely, aregiven below:

Bridge Trolley Main Hoist Aux Hoist

XOW

YOZ

DownO

Up

DownO

Up

Hoist Bridge Trolley

XOW

XOZ

DownO

Up

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NOTES

1 Markings on the crane visible from the floor, shallindicate the direction of bridge and trolley travelcorresponding to the W, X, Y and Z designations ontransmitter.

2 The maximum working range of radio control shall belimited to 40 - 50 m from the transmitter. Thislimitation reduces the likelihood of an accident causedby the crane operating beyond the operator’s visibility.

3 It is recommended that a device is fitted to the craneto give warning that the crane is under non-conductivecontrol.

4 Incorporate a limited range feature, present by meansnot available to the operator so that the crane will stopwhen the extent of that range is reached.

5 If more than one crane are provided with this type ofcontrols, only the intended crane and its motion isoperated at one time. The transmitter shall beconstructed so that it is capable of withstanding roughhandling.

14.6 Control Circuits

If the mains supply is ac and the controlcircuits are supplied at reduced voltage, thesupply to these circuits shall be from thesecondary winding of an isolating transformeror an isolating transformer and rectifier. Thetransformer frame and one pole of this supplyshall be earthed and the contactor and relaycoils shall be connected to this pole. An earthedscreen shall be provided between the primaryand secondary winding. The primary windingand unearthed pole of secondary winding of thetransformer shall be protected by fuse in lineconnection. Effective means shall be providedto prevent mal-operation owing to short circuitsor earth faults.

14.7 Rectifiers

On ac cranes, if dc supply is required, rectifiersshall be provided for supplying the controlcircuit, brakes and magnets. These rectifierunits shall be of adequate capacity to supplythe full dc loads required continuously. Theyshall be of suitable construction and mountingto withstand heat, dust, shock and vibration.Silicon type rectifier units shall be preferred.Adequate fuse protection shall be provided forthe rectifiers. Rectifiers/thyristors used formagnets shall be protected against switchsurges.

14.8 Control for dc supply

When a dc supply circuit is used, motor acts asa generator in the lowering direction, thecontrol shall be such that:

a) motor shall not exceed a predeterminedmaximum revolutions per minute,

b) progressive degrees of braking is provided,

c) adequate light hook lowering speed isprovided,

d) the brake is prevented from beingreleased by back emf of the motor whenpower supply is interrupted, and

e) the electro-mechanical brake isautomatically applied when circuitbreaker or contactor is opened.

14.9 Braking Controls

When an electro-mechanical brake is used asan emergency or parking brake or when suchan emergency or parking brake is used withhand or foot operated travel service brakes, thebrake actuating device shall remain in thecircuit when the main circuit breaker is closed.The brake shall apply automatically when thepower supply fails or when the circuit breakeris opened or on operating an emergency stoppush button or switch; but not when thecontroller handle is brought to the ‘off’ position.

The brake shall lift off when voltage at the coilsis a minimum of 85 percent of rated voltage.Provision shall be made for emergencyapplication of this brake by means of theemergency stop push button or switch.

In the arrangement of connections to thehoisting motion brake coils, means shall beprovided to ensure that when associated drivemotors are de-energized, the stored electricalenergy in these motors will not delay theapplication of the brake.

14.10 Acceleration Control

Automatic control of acceleration shall beprovided for all crane motions, unless for anymotion another control system is specified. Thehoist motion circuits shall enable any load to belowered with safety and the hoist motors shallremain under effective control with thecontroller in all positions. While calculating thenumber of rotor contactors, peak accelerating/decelerating torques and pull out torque of themotor should be taken into account.

For creep lowering speed on hoisting motion,relatively flat speed control shall be provided.

14.11 Markings on the Crane

When the control devices are other than in afixed position relative to the crane, thedesignation of horizontal directions marked onthe control device shall be marked on the craneso that it is clearly visible to the driver.

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15 PROTECTIVE EQUIPMENT

15.1 General

Suitably located efficient means shall beprovided to protect every part of a system fromexcess current and voltage to prevent danger ordamage. Enclosures having minimum degree ofprotection IP 44 shall be provided for allelectrical equipments except for motors andresistors.

15.2 Electrical Protective Device

15.2.1 General

If electrically operated contactor equipment isused for control of all crane motions, theprotective equipment shall be in accordanceeither with Scheme A, in which each motionhas separate protection, or with Scheme B, inwhich an overload of any motion trips off thecrane supply. If drum controllers or mastercontrollers are used for the control of allmotions, the protective equipment shall complywith Scheme B. Also it is more often requiredthat in master controller operated crane,overload of any motion should not trip thecomplete crane circuit, but should trip theindividual circuit.

In general, overload protection shall be ofelectro-magnetic type with time delay. Thermaloverload relays in conjunction with highrupturing capacity fuses or manual reset typeoverload relays may be provided if agreed bythe purchaser.

Where a motion is ward-Leonard controlled,provisions shall be made for:

a) protection in case of motor field failure;

b) protection against the motor creepingwhen the controller is in the ‘off’ position;and

c) tripping of the generator field circuit withsuppression of generator voltagesinstantaneously when there is an overcurrent of 250 percent in thegenerator-motor loop; or after a time-lagwhen there is a sustained over current oflower value.

Operation of any of the above protective devicesshall automatically apply the electro-mechanical brakes on the relevant motion. Ifother systems of control or mixed systems arespecified, the protective equipment shall be inaccordance with the recommendations of thecontrolgear manufacturer. An indelible circuitdiagram of the protective equipment shall beprovided in the electrical equipmentcompartment.

15.2.2 Protective Device Common to all Motions

As minimum equipments of protection, electro-magnetically operated contactors or manuallyoperated circuit breakers fitted with no voltrelease, capable of cutting off the power supplyto the motion drives with under voltageprotection shall be provided. Adequateprotection against short circuit shall beprovided at each of the isolator positions. Thecircuit breaker or the main contactor shall berated to carry at least the combined full loadcurrents of motors for any two motions havinglargest powers and auxiliary loads such asmagnet, etc. If specified by the purchaser thatmore than two motions may be operatedsimultaneously, circuit breaker/main contactorshall be rated to suit the requirement. Inappropriate cases, high rupturing capacity fusemay be provided.

The circuit-breaker shall incorporate thermaland electro-magnetic overload protection devicefor protection against sustained overload andshort circuit condition. If adequate protectionagainst short circuit is to be provided at eachisolating positions, there will be either HRCfuses or MCCB/ACB in each isolating position.As HRC fuses may lead single phasing, onlyMCCB should be provided in each isolatingposition. The circuit breaker or main linecontactor should not be rated to carry magnetfull load current as magnet supply is takenbefore the circuit breaker/main line contactor.The breaker shall have adequate rupturingcapacity to withstand and clear fault current ofthe system. If specified a suitable control circuitmay be provided for this circuit-breaker toprevent it from being closed when the maincontactor of a particular motion has failed toopen, although the corresponding controller hasbeen brought to its ‘zero’ position.15.2.3 Scheme A — Protective Device forIndividual Motions

The provision of overload protection shall bewith adjustable inverse time log overloadrelease. The minimum provision of overloadprotection shall be such that all supply linesexcept one to each motion shall be providedwith adjustable inverse time-lag overloadreleases. These shall be connected as close aspossible to the contractors they control andshall be set to trip the circuit of the motioncontrolled when carrying 200 percent of the fullload current of the motor, after a time-lag of notmore than 10 s.

It shall not be possible to reinstate the currentsupply to the contactor closing coils of a motionuntil the master controller for that motion isreturned back to the ‘off’ position.

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15.2.4 ac Instantaneous Release Single PoleOver Load : Protective Device for IndividualMotions

Any motor having its power less than one-thirdthat of the largest motor and served by thesame common overload release, shall beprotected by a separate overload release.However, normally instantaneous release ofoverload relays are not used for individualmotion and circuit breaker is tripped by its ownoverload. In crane with circuit breaker overloadprotection is provided by circuit breaker.

Adjustable overload releases shall be providedto trip the main contactors or circuit-breakersand shall be connected as close to them aspossible. The minimum provision for overcurrent protection shall be as given below:

a) one instantaneous release in a commonline feeding all motions set to trip themain contactors or circuit breakersinstantaneously when the current rises to250 percent of the value specified above;and

b) one inverse time-lag release in each otherline feeding each motion, set to trip therespective motion when carrying 200percent of the full load current of the line,after a time-lag of approximately 10 s.

It shall not be possible to reinstate the currentsupply to the common main contactor closingcoils, or complete the under voltage circuit ofthe circuit breakers until the master controllersfor all motions are returned to the ‘off’ position.

15.3 Protective Devices for Motor Circuits

The number of overload devices and theirposition shall normally be in accordance withthe arrangements shown in Table 14. Ifspecified by the purchaser, other arrangementsgiving protection not less than any of theseshall be considered as complying with thespecification.

15.4 Contactors

Reversing contactors shall be interlocked,preferably mechanically as well as electricallyso that only one directional contactor can be inthe closed position.

15.5 Control Switch Fuse

Operating coil circuit of the main contactor orcontrol contactor in case of cranes with circuitbreaker. A double pole control switch fuse shallbe connected in the operating coil circuit of thecontactor. Miniature circuit-breaker as analternative to control switch fuse may also beused.

15.6 Emergency Switches

A mushroom head push button or a prominentswitch for emergency stop shall be provided ateach control facility to switch ‘off’ the totalcrane supply or to de-energize the maincontactor common to all the motion drives. Inthe case of dc cranes, rheostatic braking shallbe applied to the hoist motions. When anycircuit-breaking device is open no main pole onthe nominally dead side shall be made alive bya parallel circuit in emergency.

The emergency switch shall be so located as tobe readily available for prompt use by theoperator in case of emergency. If specified bythe purchaser or when the crane span is largerthan 20 m, the number of emergency stopsshall be more than one. A reset button shall beprovided if required by the purchaser. Theemergency stop push-buttons or switches shallbe connected in the operating coil circuit in thecase of a contactor and in the under voltagerelease circuit in the case of a circuit breaker.

15.7 Off-Position Interlocking

Electrical interlocking shall be provided toprevent inadvertent starting of the motions, inthe case when power is lost, without thecontroller being brought to the ‘off’ position onrestoration of the supply.

15.8 Pilot Lamp

A red pilot lamp shall be connected to indicatethat the crane is ready for operations and itshall be so located that it is visible to theoperator. The pilot lamp shall be connected sothat it indicates whether the control supply isON or OFF or the contactor is CLOSED orOPEN.

15.9 Thyristor Control Main Features

a) The thyristors shall be protected by fastacting semiconductor fuses having 12 × t

Table 14 Normal Requirements for Number of Protective Devices

for Circuit

dc Supply 3-Phase acSupply

No Line Earthed One Line Earthed

2 per motion in separate lines

1 per motion connected in the non-earthed line

3 per motion in separate lines

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value considerably lower than that of thethyristors. These fuses shall becontinuously monitored so that blowing ofany fuse shall result in tripping of thepower circuits.

b) The thyristor shall be suitable to carry atleast 200 percent of the drive motorcurrent rated S3-40 percent. The PIV ofthe thyristor shall be 2.5 times the systempeak voltage appearing across thethyristors. The factor 2.5 has beenselected taking into account the linevoltage variations.

c) Each thyristor shall be protected by RCsnubber circuits so as to absorb the surgesgenerated out of external line surges inconsultation with the user.

d) The drive system shall be protectedagainst overload by means of thermaloverload or oil dash pot of magneticoverload type with inverse characteristicshaving adjustable setting range. It shallalso be protected against over current bymeans of instantaneous acting overcurrent relays having a setting range of200 to 400 percent of the drive ratedcurrent. Solid state overload protectionmay be used subject to the agreement ofthe purchaser. Preferably thermaloverload protection to be used instead ofmagnetic overload relays as the thermaloverloads have a reset time which wouldprevent the drive from restarting backimmediately.

e) Switching-off of reversing contactors shallbe done at near zero current. This is to bedone by ensuring that the stop/trippingcommand first inhibits the thyristorcontroller and then switches ‘off’ thereversing contactors. This requirementwill not be applicable if the reversing isthrough thyristors.

f) In the case of overloading or the singlephasing of the synchronising supply, thecircuits shall be tripped immediately.

g) Whenever armature reversal (in case ofthe dc drive) or stator reversal (in case ofthe ac drive) is to be done through thereversing contactors, the drive shall beprotected against the free fall conditionsat the time of switching on and reversalsby having the prefered switching state ofthe reversing contactor. The drivecontroller shall have suitable provisionsfor preventing load drifts at the time ofstart and stop.

h) For achieving smooth acceleration of thedrive mechanism suitable ramp generatorcircuit shall be available with thecontroller.

j) Wherever necessary, suitable derationwould be considered for a.c./d.c. motors inconsultation with the thyristor controllermanufacturer and the motormanufacturer.

k) The control circuits shall be so designedthat the brakes are applied at around thezero speed.

m) Test points shall be available in thecards.

n) In case of wide deviation of the speed inactual value from the set value, the circuitshall trip the mechanism immediately.During acceleration or deceleration periodsuch tripping shall be prevented byadjustable time setting.

p) Thyristor control shall be suitable foroperation at vibration levels andenvironments encountered in the craneoperation.

q) If specially required by the purchaser, thedrive motor shall be protected againstoverheating by means of thermistorsembedded in the motor winding. Matchingthermistor for trip relay shall be providedby in the control panel. The embeddedthermistors are best for preventingoverloads and subsequent overheating ofthe motor as these thermistors give thecorrect thermal image of the motorirrespective of the current carried.

r) Wherever a.c. phase controllers are to beparalleled for load sharing, the convertoroutputs shall be paralleled only at the loadend and not at the convertor end.

15.11 Special Protection for Direct Current Drive System

a) To minimize excessive rate of rise ofarmature current and radio frequencyinterference, commutating chokes withsufficient inductance shall be provided onthe ac side so that PU (inductive drop)across the choke lies between 2 to 4percent. Where isolating transformer isused, commutating chokes are notnecessary.

b) To prevent excessive wear and tear of thecommutators, the ripple content of the dcoutput shall be minimized by providingsmoothening chokes of sufficientinductance depending upon motor design.

c) In case of the four quadrant drives, to

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protect against inverter commutationfailure during regenerating mode, branchthyristor fuses shall be used. However,where it is not possible to use branchthyristor fuses, there shall be at least onefast acting semi-conductor fuse on the dcside of the converter in addition to thesemi-conductor fuses on the ac side.

d) While switching on the system, thefollowing sequence shall be adhered to:

i) Synchronizing supply is switched ‘ON’,

ii) Field circuits are established, and

iii) ac/dc contractors are switched ‘ON’.

e) The drive shall be protected against fieldfailure with suitable circuits.

f) The field current shall be reduced to a safevalue during the crane idling time toreduce the heating of the motor. Thenormal field current shall resume at thestart of the drive operation.

15.12 Main Feature of Built-in Crane Weighing System (Load Cell)

a) The load cell shall be of compression typeand IP 68 protection.

b) The power supply shall be 230 V ac or110 V ac 50 Hz single phase.

c) The load cell shall be placed in such a waythat the load which is inert on theequalising pulley/bar is transferred to thisload cell by a pivot assembly.

d) The built-in crane weighing system shouldhave local indicator, processor based type,LED display, IP 55 protection, shall belocated on the control cabin of the crane.

e) The built-in crane weighing system shouldhave remote indicator, LED display type,minimum visibility range of 50 m, shall belocated on the crane girder.

f) The resolution shall be in the order of 5 kg.

g) The system shall have the provision oftripping the circuit in case of overloadingthe cranes and should serve on anadditional overload safety device.

16 ISOLATION

16.1 General

Means shall be provided at easily accessible

positions on the crane for isolating the cranefrom the power supply close to the connector orterminal box in the case flexible cables areused. These shall take the form of isolatingdevices fed in parallel as follows:

a) for motion drives,

b) for auxiliary circuits, and

c) for the lifting magnet, if fitted.

16.2 Isolating Device for Motion Drives

The isolating device for the motion drives shallbe capable of interrupting the stall current ofthe largest electric motor fitted to the crane orcombined full load currents of the motors of anytwo motions of the crane using the largestpower (kW) working together which ever ismore and working together with auxiliaryloads. Main switches used for isolating shallcomply with the relevant Indian Standards.This isolating switch shall be unfused, unlesshigh breaking capacity fuse protection isspecified.

16.3 Isolating Switches and Isolators

16.3.1 Cabin Operated Cranes

For all cabin operated cranes a main isolatingswitch shall be fitted in the cabin or adjacent toit capable of cutting off the supply for all powerdriven and associated equipment on the crane,except auxiliary connections such as warninglights, lighting, fan and heating circuits, airconditioners, magnet circuits andcommunication circuits.

When the operator’s cabin is fitted to the trolleyand moves in relation to the main cranestructure, an isolating switch outside the cranecabin shall be provided in addition to theisolating switch in the operator’s cabin.

16.3.2 Pendant Controlled Cranes

For pendant controlled cranes, an isolatingswitch as mentioned in 14.4.3 shall be fitted.

16.4 Isolators for Auxiliary Circuits

All auxiliary connections, when required, shallbe supplied from the live side of the mainisolating switch and shall be controlled byseparate isolating switches with cartridge fuseprotection. If the supply voltage exceed240 volts and if lamps are operated in series,double pole isolating switches shall beprovided.

16.5 Interlocking

If the main isolating switch is combined withthe crane protective panel, it shall be

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mechanically interlocked with the door givingaccess to the panel and the incoming terminalsshall be screened to prevent accidental contactwhen the door is open. When not so combined, apair of pilot lamps or other device in duplicatewith a red warning plate shall be provided tothe covers of the protective gear, other panelsand controllers not fitted with interlockingisolators. Access to the enclosures containingelectrical equipments shall require use of a keyor a tool to open them.

16.6 Isolating Switches for Down-Shop Conductors

Isolating switches for the down-shopconductors shall be provided by the purchaserat a suitable and accessible locations. The mainand additional isolating switches should be sosituated that any maintenance work orfunctional testing can be carried out withoutdanger.

17 LIFTING MAGNET AND RELATED EQUIPMENTS

17.1 General

If required by the purchaser, the crane shall befitted or provision shall be made to permit inthe future fitting of lifting magnets, magnetcontrol and protective gear.

17.2 Magnet

The type and size of magnet shall be decidedbased on the details given by the purchaser.Each magnet will be water tight and shall beprovided with a water tight terminal boxhaving the under mentioned features, howeverrectangular magnets are normally of fabricatedconstruction type also can be used as follows:

a) integral construction with magnet casing,

b) a gland through which the magnet load isbrought to the magnet terminals,

c) a cover which shall be easily removablewithout interfering with the magnet leadinlet,

d) adequate thickness of box and cover, and

e) non-linear type discharge resistor ofadequate rating and the rectangularmagnets are fabricated constructions andnice fabricated type of magnets.

17.3 Magnet Lead and Cable

The magnet lead and cable shall be flexiblethree core cables. If specified by the purchaser,

the magnet lead shall be protected by rubberhose complying with the relevant IndianStandard. The magnet lead shall be soarranged that it does not become unduly slackor taut during normal operation of the crane. Itshould be so located that magnet cable does notfoul with the rope. The use of sheaves androllers for the cable should be avoided as far aspossible. The magnet cable shall be rigidlyattached to the bottom block by a suitable cableclamp at a point above magnet coupling.

17.4 Magnet Couplings

The type of magnet coupling shall be as agreedbetween the purchaser and the crane supplier.The coupling shall comply with the followingrequirements:

a) The coupling shall be of ruggedconstruction.

b) At the moment of breaking, the contactsshall be enclosed by insulating materialand earth connection shall break last.

c) Provision shall be made to fasten thecoupling in the closed position.

d) The socket shall be connected to thesupply and plug to the magnet or magnetlead.

17.5 Cable Drum

The magnet cable drum shall be as follows:

a) arranged so that magnet cable does notfoul with the hoisting ropes,

b) such that the cable will become neitherunduly taut, nor slack enough to touch thehoist ropes or get entangled, and

c) capable of accommodating and paying outthe length of cable necessary for themagnet to reach its lowest position.

Cable drum when attached to the hoist drive, adisengagement device shall be provided. Wherepower is fed to the magnet by a brush and slipring arrangement on the magnet cable drum,two brushes per slipring shall be provided andthe rings shall have adequate clearance. Theslip ring insulation shall be of non trackingmaterial and the assembly shall be enclosed byan easily removable cover, oil-proof for indoorcranes and weather proof for out door cranes. Aspare slipring complete with brush geararrangement shall be provided if required bythe purchaser.

17.6 Magnet Control and Protective Equipment

The magnet shall be controlled either by direct-

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on-line control or potentiometer control asrequired by the purchaser. In both methods ofcontrol the magnet shall be demagnetized bycurrent reversal.

In direct-on-line control, the magnet shall beenergized by switching it across full mainsvoltage and discharge resistance shall beconnected on switching ‘OFF’.

The control shall be affected by means of amaster controller and magnetic contactorpanel.17.7 Battery Back up System

If required by the purchaser necessary andadequate battery back up system shall beprovided by the supplier. The rechargeablebattery shall keep the magnet energized till thetime the lifted load is brought to a safe location,in the case of power failure.

18 RESISTORS

18.1 General

Resistors shall be adequately protected toprevent accidental contact with live parts. Theelements shall be protected against corrosion.18.2 Rating

Resistors shall be rated such that thetemperature does not exceed the limitsspecified in the relevant Indian Standardspecification, during the operation of the craneunder service condition. The resistance andcurrent capacity of the resistors shall becomputed according to the actual torquerequirements of the motion served and not onthe motor size which may be set by thermalrequirements.

The effect of using plugging as a service brakeshall be taken into account in determining thesize of resistors. Resistors shall be ratedaccording to the service conditions and themechanical class of the crane and shallpreferably be intermittent and short timerated. The rating of the resistors shall not beless than that given in the Table 15.

NOTE — For definitions of different intermittentrating, see Annex E.

18.3 Fittings

Resistors shall be enclosed in the wellventilated housings and, wherever necessary befitted with suitable covers. They shall bemounted outside the main contactorcompartment. Resistors shall be mounted onsteel frames to withstand forces imposed by thecrane under service conditions. They will bearranged in such a way that boxes can be easilyreplaced.

The connections to the resistor terminalsshould be accessible and adjustable. Resistorassemblies shall not impede the maintenance ofthe long travel drives or access to any part onthe crane.

Resistor assemblies for each motion shall bestacked separately for the facility of inspectionmaintenance and safety.

18.4 Degree of Protection

Minimum degree of protection for the resistorsshall be IP 11 or as specified by the purchaser.

19 LIMIT SWITCHES

The limit switches shall be of self-resetting typewith in a reasonable distance travel in theopposite direction. In the case of changeover(memory) type limit switches resetting isachieved by striker moving in the oppositedirection.

Snap action limit switches when actuated shallstop the motor and shall apply the brake orshall initiate dynamic braking if provided. Theactuation of the limit switch shall trip the mainincoming circuit breaker/contactor and shalloperate an audio and/or visual warning signalif required by the purchaser.

The manufacturer should fit one or moredevices to the bridge of the crane to givewarning of the approach to the danger oranother crane. However, the purchaser canspecify about the type of devices required forhis crane so ordered. Devices using infra redlights, sound waves or limit/proximity switchesmay be used for this purpose. Limit switchesshall be so arranged that they can be readilytested.

In the case where abnormally high lifts arerequired, arrangements shall be made byproviding additional limit switches and bypassing buttons as required by the purchaser.Fast or slow speeds may be provided for liftingheights as required by the purchaser.

Cams for strikers, when used for actuatinglimit switches, shall not damage the limit

Table 15 Rating of Resistors

Mechanism Class Short Rating for Time Rated Resistors, Min

M1, M2 2

M3, M4, M5 5

M6, M7 10

M7, M8 To suit the servicecondition

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switches on over travel due to impact or inertia.

20 CABLES AND CONDUCTORS

20.1 General

Cables used for crane wiring shall comply withrelevant Indian Standard specifications. Unlessotherwise agreed, only copper or aluminiumcables shall be used for power wiring and onlycopper cables shall be used for control wiring.Single strand cables shall not be used wherecable cross sectional area is more than 6 mm2.

20.2 Minimum Size

Conductors for power wiring/control circuits toelectric motors shall have a sectional area notless than the values given below of copper orequivalent material.

a) [2.5 mm2 for Power] and [1.5 mm2 forcontrol wire] should be up to M5 Class.

b) [4.0 mm2 for Power] and [2.5 mm2 forcontrol wire] should be above M6 Class.

20.3 Protection

All cables shall be adequately protected againstmechanical damages as given below :

a) by running in conduits complying withrelevant Indian Standards, trunking or ontrays, or

b) by being clipped to the crane structure ina position where they are protected frommechanical damage, or

c) by being of armoured construction.

If cables are drawn into a steel tube, the tubeshall be medium gauge welded or solid drawnor screw jointed. For outdoor cranes exceptwhere flexible unarmoured cables are essential,cables shall be either armoured or enclosedthroughout their length in galvanized trunkingor conduit. Taped and braided varnishedcambric insulated cables shall not be used foroutdoor cranes.

20.4 Current Rating

Rating of the cable, in the circuit related tomechanism Group 8, shall be not greater thanthe appropriate values given in the relevantIndian Standard specifications for continuousduty giving due considerations to ambienttemperature, type of excess current, protection,grouping and disposition of cables and voltagedrop. Cables in circuit related to mechanism

group below M8 may be rated higher inaccordance with Table 16.

20.5 Installation

The cable and wiring system for each motionshall be independent and common return shallbe avoided. Main cables and controlled wiringshall be effectively separated. Cables shall beadequately secured to the main structure of thecrane having due regard for the weight of thecable and the possibility of vibration. Cableruns shall not be installed in a place where theywill impede the crane driver’s view or hamperthe movement of persons on the crane. Thecables shall be placed so that they are easilyaccessible. Due consideration shall be givenduring the design of the crane to makeadequate provision for cable runs and to avoidcable runs in locations where mechanicaldamage or high temperatures are likely to beexperienced. The segregation of power andcontrol cables shall be made as far as possibledepending upon the space available on thecrane and keeping or maintenance point ofview.

Where there is incidence of direct radiation ofheat, the cables shall be protected by metallicshield. Where mineral insulated metal cablesare subjected to the effects of high transientvoltage they shall be suitably protected by theuse of surge limiting devices. Cables remainingalive, when main isolator is opened, shall beseparately installed and adequately protected.Adequate precaution shall be taken to preventthe ingress or collection of water or oil in anypart of a conduit or trunking system.

20.6 Termination

Where trunking is used it shall extend into theelectrical compartment or enclosed units. Itshall be terminated as close as practicable tomotors, collector gears and controllers.Junction boxes shall be rigidly fixed to thecrane structure close to the end of the trunking.Conduiting systems shall be continuous to

Table 16 Operative Rating Cables( Clause 20.4 )

Mechanism Class

Stator Circuit Rating

Multiplied By

Rotor and Resistor Rating

Multiplied by

M1, M2 2.0 2.5

M3, M4, M5 1.7 2.0

M6, M7 1.4 1.5

M8 1.1 1.1

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switch boxes and conduit outlets. Cable tailsshall be adequately insulated and mechanicallyprotected.

21 AUXILIARY REQUIREMENTS

21.1 Lighting on the Crane

Necessary lighting arrangement for approachesand for carrying out maintenance work withoutdanger shall be provided by the cranemanufacturer in consultation with thepurchaser. The nominal voltage of lightingcircuits shall not exceed 250 V.

If hand lamp is provided it shall not beconnected to a circuit exceeding 250V dc or 25Vac supply. In the case of an ac circuit handlamp shall be fed through a double woundisolating transformer with some part of thesecondary winding earthed. The primarywinding of the transformer shall be controlledby a double pole switch. Fuses shall be providedin each pole of the primary circuit and one poleof each of the secondary circuits.

21.2 Cab Lighting

The cab and the panel room shall be providedwith adequate lighting.

21.3 Under the Bridge Lighting

Under bridge lighting if required by thepurchaser shall be mounted on shock absorbersand so installed that they can be servicedeasily.

21.4 Other Provisions in the Cab

As required by the purchaser fans,air-conditioners or cab heating arrangementsshall be provided by the crane manufacturer.

21.5 Crane Warning Signals

If required by the purchaser, the crane shall beequipped with warning lights on both sides ofthe crane and/or sound signals to indicateapproach of the crane or hock. Each warninglight fitting shall contain two electric bulbsconnected in parallel.

Each fitting shall be provided with ananti-vibration mounting and shall beaccessible. They shall not interfere with thedriver’s vision and shall be readily visible to theconcern persons.

22 CONDUCTORS AND CURRENT COLLECTORS

22.1 General

The type of current collecting system for longtravel and cross travel motion shall be providedas required by the purchaser. Bare conductors

used for the purpose of picking up current shallbe placed out of reach or protected to preventaccidental contact by persons operating,maintaining or inspecting the crane. No bareconductors should be placed in the inner middleof grinder all types of conductors system shouldbe accessible for maintenance and replacement.The protection may be in the form of localguards fitted on the crane.

22.2 Bare Copper Wires

Bare copper wires when used as conductorsshall comply with IS 282. Wires smaller than25 mm2 of equivalent copper area shall not beused. Intermediate supporting insulators forthe copper wires shall prevent wires leavingthem under any condition. Adequate tensioningdevices shall be installed at the wire ends andthere shall be no possibility of adjacent wirescoming into contact.

22.3 Trailing Cable Arrangement

In the trailing cable arrangement theconductors shall be insulated flexible single ormultiple core cables as specified in 20 withpermanent termination on the fixed part andmoving part. The flexible trailing cables shallhave sufficient length and shall be supportedon trolley with clamps. The trolley shall runfreely on a guide without undue stresses orwear on suspended cables and cable trolleysshould have four wheels fitted with antifrictionbearings.

22.4 Rating

Unless otherwise specified the maximumcurrent density shall not exceed 0.42 A/mm2 forrolled steel sections, 1.2 A/mm2 for aluminiumsections and 2.5 A/mm2 for copper sections. Thegap between the current collector and adjacentlive or earth part shall not be less than 50 mm.

22.5 Down-Shop Lead Arrangement (Long Travel Current Collecting System)

22.5.1 General

Down shop lead arrangement using copper,aluminium or steel sections with or withoutshrouding or by using flexible trailing cablearrangement may be used. Use of shroudedconductors, where possible is recommended.

22.5.2 Conductors

Current collecting system shall be providedeither by the purchaser or by the cranemanufacturer as agreed by them.

Cranes operating on bare conductors shall be

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equipped with adequate guards to preventropes or suspended load coming in contact withthe live conductors due to swing of the hookblock. Down-shop conductors also shall bescreened to prevent contact while handling longlengths of conducting materials from floor.

22.5.3 Current Collectors

Unless otherwise agreed to, all collectorassembly shall be supplied by the cranemanufacturer. The purchaser shall furnishrelevant details depending upon themanufacturers scope of work. Collector rollersor shoes shall be so designed as to avoidsparking and shall be easily replaceable.Collector assembly shall be mounted on a rigidstructure on the crane bridge. Necessary safeand convenient access shall be provided formaintenance or replacement of the collectors.

22.6 Cross Travel Current Collecting System

22.6.1 General

Cross travel current collecting system shall bewith bare conductors or with shroudedconductors or with trailing cable arrangement.The collection system shall be provided by themanufacturer.

22.6.2 Conductors

Cross travel conductors for the main crab shallbe mounted on the main bridge platform andnot inside the main girders. Conductors forauxiliary crabs shall be mounted suitably abovethe level of auxiliary crab rails. Cross travelconductors shall be arranged so that they areall accessible for maintenance from at least oneside along the whole length. Bare conductorsmounted on the bridge adjacent to a walk wayalong the bridge shall be completely screenedfrom the walkway.

22.6.3 Collector Assembly

Collector assembly shall be rigidly mounted onthe crab and shall be provided with reasonableaccessibility to all parts for maintenancepurpose.

23 EARTHING

23.1 General

The crane structure, motor frames, and metalcases of all electrical equipment includingmetal conduit or cable guards shall beeffectively connected to earth complying withIndian Electricity Rules ( see IS 3043 ). Aflexible metallic tube or duct may not form aneffective earth connection. The crane wheelsshall not be used as means of earthing.

Where the crane is connected to the supply byflexible cord or flexible cable, the crane shall beconnected to earth by means of a separateearthing conductor enclosed with the currentcarrying conductors.

Travelling cranes connected to the supplythrough collectors shall be effectively earthedthrough a fourth lead or through a set ofcollectors sliding on the gantry rail withreference to IS 3043.

The purchaser shall arrange for the earthing ofthe gantry and/or the long travel earthconductor.

23.2 Control Circuit Earthing

One end of the secondary winding of controlcircuit transformer shall be earthed. One end ofthe coil of all relays and contactors shall beconnected to earth side of the control circuitsupply and this connection shall not beinterrupted by any fuse or contact.

In the case of dc control circuits one pole of therectifier shall be earthed.

23.3 Magnet Earthing

The magnet frame shall be bonded to the crabby the earth connection via the magnet lead,the magnet coupling, the magnet cable and anextra slip-ring on the cable drum.

24 ELECTRICAL EQUIPMENTS LOCATED ON THE CRANE BRIDGE

24.1 General

Electrical equipments mounted on bridgeplatform shall be enclosed in suitable enclosurewith provision for easy access to the partsinside. The units shall not impede themaintenance of the long travel drives. Thecontrol panels or units shall be so spaced thatefficient maintenance is possible. They shallwithstand the mechanical forces imposed bythe crane under service conditions. For cranesworking in open yard, electrical equipmentsshall be of weather-proof construction for theduty. Control panels and other electricalequipment shall be so located that there is nochance for oil or grease falling on them. Thethorough fare between any portion of the craneand the exit platform shall not be impeded byany control unit. However, also refer the belowgiven Table 17 for information may suitablyused for the enclosers where discussed.

24.2 Identification of Circuits

All switches, fuses, panels, controllers, resistorsconnectors and other electrical elements of

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controller panels shall be adequately labelled ormarked by furnishing functional nomenclatureto facilitate identification of the circuit. Allmain and control wires and conductors shall beferruled and numbered at both ends as perdrawing for quick identification. All equipmentterminals shall be numbered and tagged.

25 DRAWINGS

A wiring diagram of the crane shall be suppliedby the manufacturer. The diagram shall givethe rating of each motors, the cable sizes andsuch other information which will facilitateinspection and maintenance of the crane. Allelectrical elements shall be designated byfunctional nomenclature and numbered foridentification. All main and control wires andterminals shall be numbered to facilitatewiring and identification while maintaining. Aschematic diagram shall also be supplied forcontactor controlled cranes along with the listof parts used. In addition to the drawings thefollowing drawings and documents may also beprovided as given below:

a) External termination drawings and cableschedule, and

b) GA drawings of all electrical items.

Table 17 Information for Enclosures

Equipment In-door Out-door

Control panel IP 54 (withdouble door)

IP 55 (withdouble door)

Limit switches IP 54 IP 55

Resistances IP 11 IP 33

Motor IP 54(without cover)

IP 55(with cover)

DATA W1 W2 W3 W4 ED1 ED2 ED3 ED4 S1 S2 CD1 CD2

SPECIFICATION

ACTUAL

TOLERANCE

FIG. 6 CRANE DIMENSIONS ( Continued )

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DATA TS1 TS2 TS3 TS4 TS5 TS6 TS7 REMARK

SPECIFICATION

ACTUAL

TOLERANCE

CRANE LOCATION :

CAPACITY AND TYPE :

CRANE MANUFACTURER :

ORDER NUMBER :

DATE OF INSPECTION :

PLACE OF INSPECTION :

FIG. 6 CRANE DIMENSIONS

USE WATER LEVEL TO TAKE READING

GRINDER h4 h3 h2 h1 L H1 H2 H3 H4

DRIVING

TRAILING

a) DEFLECTION DUE TO DEAD LOADOF BRIDGE GIRDER

::

b) DEFLECTION DUE TO TROLLEY WEIGHT :

c) DEFLECTION DUE TO RATED LOAD :

d) ACTUAL CAMBER :

e) ACTUAL DEFLECTION :

REMARKS :

FIG. 7 BRIDGE CAMBER

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SECTION 4 INSPECTION AND TESTING

26 INSPECTION PROCEDURE

26.1 General

If required by purchaser and specified in thecontract, the purchaser or his authorisedrepresentative shall have access to themanufacturer’s works at all reasonable timesfor the purpose of witnessing the manufacturer,inspection and testing of all products concernedand/or the complete crane.

Any work found defective or which is not inaccordance with the drawings or of the terms ofthis code and/or contract may be rejected by theinspector ( see Fig. 6, 7 and 8 ).

26.2 Test at Manufacturer’s Works

All electrical and mechanical equipment shallbe tested in accordance with the appropriateIndian Standard at either the crane maker’s orequipment manufacturer’s works and testcertificates provided, if required by thepurchaser.

If required by the purchaser and specified inthe contract, the crane shall be tested atmanufacturer’s works under full load and 25percent overload of hoisting and cross traverse

motions. Travelling gear may be run light tocheck shaft and gear alignments. If load test iscarried out all the manufacturer’s premises, itshall be carried out at the purchaser’spremises.

Any test required by the purchaser beyondthose called for in the appropriate IndianStandard shall be subject to mutual agreementand shall be carried out at the purchaser’sexpense.

26.3 Trolley Movement Over Bridge Girder

a) Whether all the 4 wheels are incontact with the rails at allplaces ........................................

26.3.1

DATA W1 W2 S1 S2 D1 D2 REMARKS

SPECIFICATION

ACTUAL

TOLERANCE

REMARKS :

FIG. 8 TROLLEY DIMENSIONS

Quality of Alignment of

Geared Couplings

Axial Misalignment

( in mm )

Angular Misalignment ( in degree )

a) Main hoist .................... ....................

b) Auxiliary hoist .................... ....................

c) Cross traverse .................... ....................

d) Long travel .................... ....................

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26.3.2 Condition of Cable Trolleys

26.3.3 Performance of Mechanisms ( EachMechanism should be Run for 30 minContinuously for this Test )

a) Long travel (No load running on sleepers oron Test Bench)

b) Main hoist

c) Auxiliary hoist

d) Cross traverse

26.3.4 Hardness

a) Long travel wheels ........................................

b) Cross traverse wheels ...................................

c) Permissible values .........................................

26.3.5 Material of Wheel for LT, CT ...................

26.3.6 Hardened ..................................................( Process of hardening )

26.3.7

26.3.8

26.3.9 Idle Running and Speed of the Motor

26.3.10 Electrical

Motors (idle running and measuring the noload and full load current) :

a) Are they provided with ball bearings: .............. ..............

b) Are they fitted with single flanged wheels: .............. ..............

c) How many wheels per trolley: .............. ..............

d) Number of trolleys: .............. ..............

i) Noise level from .......................................gear box

ii) Oil leakage through ................................input and output shaft

iii) Linear speed of wheel .............................treated at full speed

iv) Hardness of gears/ ...................................pinion

v) Material of gears/ ....................................pinion

i) Noise level from gear box ........................

ii) Oil leakage through shafts .....................

iii) Surface speed of wire rope drum ............

iv) Hardness of gears/pinion ........................

v) Material of gears/pinion ..........................


ii) Oil leakage through shafts .....................

iii) Surface speed of wire rope drum ............




ii) Oil leakage ...............................................

iii) Linear speed ............................................



Painting Actual As per Specification

a) Prime coat ............. .............

b) Finishing first coat ............. .............

c) Second coat ............. .............

Bolt Holes Alignment ( Tolerance level of bolts

and holes )

Fit bolts ( Reamed holes )

a) Bridge girder splice ..................

b) Gantry leg spice ..................

c) End carriage splice ..................

d) End connection (End carriage and girder)

..................

a) Main hoist ..................................

b) Auxiliary hoist ..................................

c) Cross traverse ..................................

d) Long travel ..................................

a) Main hoist ..................................

b) Auxiliary hoist ..................................

c) Cross traverse ..................................

d) Long travel ..................................

(variable speeds of different motion under no

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load and load condition)

26.3.11

26.3.12 Wiring

26.3.13

a) Is plugging and reversing functioning ?

b) Is creeping functioning ?

c) Is counter torque lowering workingsatisfactorily ?

d) Is zero speed monitor functioning ?

26.3.14

26.3.15 Check the Functioning and Observe

26.3.16 Check the Functioning of Accessories

Main Hoist

Auxiliary Hoist

Cross Traverse

Long Travel

I notch .......... .......... .......... ..........

II notch .......... .......... .......... ..........

III notch .......... .......... .......... ..........

IV notch .......... .......... .......... ..........

V notch .......... .......... .......... ..........

Rated speed as per specification .......... .......... .......... ..........

Control Panel As per Drawing

Actual( IP 54 or IP55 )

a) Size ............... ...............

b) Powercontractor sizeand rating

............... ...............

c) Rotor contractorsize and rating

............... ...............

d) Terminal blockssize

............... ...............

e) Types of wiring ............... ...............

f) Cable(aluminium/copper)

............... ...............

g) Spacing of thecontractors andtimers

............... ...............

h) Multi hingeddoors

............... ...............

j) Type of beedingprovided

............... ...............

Crane Trolley Cabin

a) Any defect noticed ? .......... .......... ........

b) What type of wiring ? .......... .......... ........

c) Rectification needed ? .......... .......... ........

d) Whether cabin wiring completed ? .......... .......... ........

e) Are the differentmotions as perwiring diagram ?

.......... .......... ........

Resistors Main Hoist

Auxiliary Hoist

Cross Traverse

Long Travel

a) Rating andvalue ofresistancein each step ........ ........ ........ ........

b) What is thetype ofresistorused ........ ........ ........ ........

c) Is resistoras perspecifica-tion ? ........ ........ ........ ........

d) Lugs to beprovided intheterminals ........ ........ ........ ........

e) Heatingconditionduring noload andfull loadtesting

........ ........ ........ ........

Main Hoist

Auxiliary Hoist

Cross Traverse

Long Travel

a) Contractors ........ ........ ........ ........

b) Timers ........ ........ ........ ........

c) Limitswitches

........ ........ ........ ........

d) Overloadprotection

........ ........ ........ ........

e) Controllers ........ ........ ........ ........

a) Ceiling fan .....................

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26.3.17 Insulation Tests

After erection but before the crane is connectedto the supply, the insulation of the electricalequipment shall be tested by a suitableinstrument and any defects revealed shall berectified. The voltage required for theinsulation resistance test shall be d.c. voltagenot less than twice the rated voltage of thesystem concerned and all phase shall bechecked for each crane motion or system. Anyreading less than 0.5 M ohm obtained with aninsulation resistance tester shall be verified.The wiring under test shall be subdivided untila reading higher than 0.5 M ohm is obtained.Failure to obtain higher reading shows anunsatisfactory state of the insulation and henceshall be rectified.

NOTE — A reading below 0.5 M ohm obtained withsuch a tester may indicate that unduly low proportion ofthe prescribed test voltage is in fact being applied.

If an installation has been subdivided for test purposeseach sub-division shall meet the requirements. Theinsulation resistance of each wiring circuit exclusive ofconnected apparatus shall be not less than 2 M ohm. Ifnecessary, it shall be permissible to disconnectindividual items of equipment making this test.

26.3.18 Test Certificate

If specified by the Government of the State inwhich the crane is to be installed, the testsshall be carried out in the presence of thecompetent authority appointed, by theconcerned industrial safety department of thegovernment. The crane shall be put in use onlyafter clearance and acceptance certificate isissued by the competent authority. Thepurchaser shall arrange to ensure presence ofthe competent authority at the time of testing.

The manufacturer shall issue a test certificateclearly indicating the tests carried out andresults obtained.

27 GENERAL REMARKS

27.1 Welding Inspection Procedures

27.1.1 Visual Examination

Refer Table 18 for verification.

27.1.2 Proforma for Welding Profiles Certificate( see Table 19 )

27.1.3

a) Radiographic procedure

i) Radiographic shall be made by eitherX-ray or isotope radiation methods.

b) Warning bell .....................

c) Underbridge lighting .....................

d) Operator’s seat .....................

Table 18 Certificate

Sl No.

Condition Accep- table/Not

Accep- table

Reason for Not Accep- table

(1) (2) (3) (4)

i) The weld has no cracks

ii) Complete fusion exists between adjacent layers of weld metal, and between weld metal and base metal

iii) All crates are filled to full cross section of the weld

iv) Weld profiles are in accordance with Fig. 9

v) Permissible frequency and size of piping porosity in fillet welds shall be limited as follows:

a) For primary welds not more than 1 mm pore in each 102 mm length and no larger in diameter than 2.4 mm

b) For secondary welds the sum of the diameters of piping porosity shall not exceed 9.5 mm in any linear mm of weld and shall not exceed 19 mm in any 305 mm length of weld

vi) The actual size of a portion of continuous fillet weld, 9.5 mm or larger, can be under the normal required fillet weld size by 1.6 mm without correction, provided that the under size portion does not exceed 10 percent of the weld length

vii) Primary groove welds must have no piping porosity

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b) Acceptability of Radiographic Welds

27.1.4 Ultrasonic Test, Magnetic Particle andLiquid Penetrant Tests as per ASTM E164,ASTM E709 and ASTM E165

a) Ultrasonic examination of welds,

b) Ultrasonic testing procedures acceptancecriteria and reports,

c) Magnetic particle examination of welds A,and

d) Liquid penetrant examination of welds.The recommended forms for reporting theresults of the above tests as shown in theformats attached.

27.1.5 Repair and Correction of Discontinuities

a) Overlap or excessive convexity — Removeexcess weld metal.

b) Excessive concavity of weld or crater andunder size welds — Prepare surfaces anddeposit additional weld metal. All slag

Table 19 Certificate( Clause 27.1.2 )

Sl No.

Condition Acceptable/ Not

Acceptable

Remarks

(1) (2) (3) (4)

i) The faces of the fillet welds

(a) Convex

(b) Flat

(c) Slightly concave(concavity must notexceed the sum of 0.1s +1 mm where is the actualsize of the fillet in mm)

ii) a) Groove welds must befree of thediscontinuities.

b) In case of butt and cornerjoints, the reinforcementheight R, must notexceed 3 mm for metalthickness of 51 mm andunder 5 mm for metalthickness over 51 mm

iii) Where the surface of buttjoints are required to beflush, the thickness ofthe thinner base metal orweld metal shall not bereduced by more than0.8 mm

iv) Under cut depth shallnot exceed 0.8 mm or7 percent of the basemetal thickness

v) Welds shall be free fromoverlap

ii) The quality level of inspection forradiographs shall be 2.2 T, except thatthe dia of the 2T penetrate meter holdneed not be less than 1.6 mm for X-ray or2.4 mm for gamma ray radiographs.

iii)Radiographs shall have a H and Ddensity between 1.5 and 3.5.

iv) Two or more penetrate meters shall beused for each radiographs on a film 254 ormore in length. Only one penetrate meterneed be used for radiographs on film lessthan 254 mm in length.

v) Radiographs shall be made with a singlesource of radiation approximately centred

with respect to the length and width ofthe area being examined. The distancefrom radiation source to the film shall notbe less than 7 times the maximumthickness of weld being examined, andthe rays shall not penetrate the weld atan angle greater than 26.5°. From a lineperpendicular to the weld surface. Thefilm, during expose, shall be as close aspossible to the surface of the weldopposite to the source of radiation.

i) Welds subject to radiographicexamination shall first be visuallyexamined to check the cracks andwelding profiles.

ii) The greater dimensions of the porosity orfusion type discontinuity indications thatare 1.6 mm or larger shall not exceed thesize.

iii) Discontinuities meeting requirements of1 and 2 and having a greatestdimensions of less than 1.6 mm arenevertheless not acceptable if the sum oftheir greatest dimensions 9.5 mm in anylinear 25 mm of weld.

iv) The limitations for 38 mm groove weldeffective throat shall apply to all weldswith larger effective throats.

v) A recommended form for reporting theresults of radiographic examination isshown as per format attached ( seeFig. 9 ).

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METAL THICKNESS WELD REINFORCEMENT

†(mm) R(mm)

50 mm OR LESSOVER 50 mm

3.18 mm4.77 mm

WELD SIZE TOLERANCES

WELD SIZEIN (mm)

WELD SIZE TOLERANCE IN (mm)

UNDER 10 mm – 0+ 1.6

10 mmOR LARGER

– 1.6+ 3.18

FIG. 9 ACCEPTABLE AND UNACCEPTABLE WELD PROFILES

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shall be removed and the adjacent base metalshall be cleaned before additional welding.

c) Cracks in weld or base metal — Determinethe extent of the cracks by dye penetrantmagnetic particle inspection or othersuitable means. Remove the crack andadjacent sound metal for a 51 mm lengthbeyond each end of the crack and thenreweld.

d) Under cutting — Under cutting may berepaired by grinding and blending or bywelding. Grinding should be performedwith a pencil type grinder. Blending shallbe done with a slope not to exceed 1 in 3 onplates of 13 mm thickness and above, upto 7 percent reduction of base materialthickness is permitted. When undercut isto be repaired by welding, prepare thesurfaces and then deposit additional weldmetal.

27.1.6 Base Material Repairs

a) Defects in edges of plate — If a defect isfound in a plate edge that excess thelimits, shall be removed and repaired.

b) Arc strikes and temporary attachment —Areas : Arc strikes or severed temporarywelds in critial locations, must be groundsmooth to ensure that no abrupt change insection exists.

c) Removal of defective areas — The removalof weld metal or portions of the base metalmay be done by machining, grinding,chipping, oxygen gouging or air carbon arcgouging. It shall be done in such a mannerthat the remaining weld metal or basemetal is not nicked or undercut.

Unacceptable portions of the weld shall beremoved without substantial removal ofthe base metal.

Additional weld metal, to compensate forany deficiency in size, shall be depositedusing low hydrogen electrodes.

d) Distortion and camber — Membersdistorted by welding shall be straightenedby mechanical means or by carefullysupervised application of a limited amountof localised heat. The temperature ofheated areas, as measured by approvedmethods shall be limited to that imposedby the materials exposed to the heat, but itshall not exceed 590°C for quenched- andtempered steel nor 890°C for other steel.

e) Correction of improperly fitted and weldedmembers — If a weld is found to beunacceptable after additional work hasrendered it inaccessible, or new conditionmake correction of the unacceptable welddangerous or ineffetual, or originalconditions shall be resorted by removingwelds or both, before the corrections aremade.

28 TESTING

28.1 Preliminary Tests

The preliminary tests shall be done before thehoist block is reeved. Test the various methodsas follows. Close the runway, disconnect theswitch, the main crane disconnect switch, andthe individual motor and accessory switches inthat order.

28.1.1 Hoist ( Main Hoist and Auxiliary Hoist )

a) Place master switch in 1st point ‘hoist’position.

b) Observe the contactor for proper sequenceand direction of hoist drum rotation. Ifoperating correctly the speed may begradually increased.

c) If hoist contactor and rotation is notcorrect, shut off power, reverse two leadson the main line collectors or on the hoistmotion (whichever is incorrect), to obtainthe correct phasing. Restore power therepeat step (a) and (b).

d) After checking hoisting, return masterswitch to neutral position and observebraking action, readjust if needed.

e) Place master switch in ‘lower’ 1st pointand observe if correct motion andcontactor sequence occurs.

f) Reset hoist timers, if needed.

g) Speed points shall be for accelerating onlyand shall not be used for running anydistance. Maximum time for accelerationis 15 s, unless special equipment isprovided. If held any longer, resistordamage may occur.

h) The above steps (a) to (g) shall be repeatedfor auxiliary hoist same as main hoist.

28.1.2 Cross Travel Motion

a) Place master switch in I point ‘Trolleytravel’ position.

b) Observe contactor sequence and directionof travel through full range of master

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switch. Reverse phasing, if necessary.

c) Allow trolley to move entire length ofbridge span, are fully watching alignmentof trolley collector pole and bridgeconductors and also watching for anyinterference with building and buildingequipment. Do not run trolley into endstops.

d) Adjust end limit switch trip.

e) Reverse master switch and repeat (a) to(d).

f) Reset trolley timers, if needed.

28.1.3 Bridge Motion ( Long Travel )

a) Place master switch in 1st point ‘Trolleytravel’ position.

b) Observe contactor sequence and directionof travel through full range of masterswitch. Reverse phasing, if necessary.

c) Allow trolley to move entire length ofbridge span, are fully watching alignmentof trolley collector pole and bridgeconductors and also watching for anyinterference with building and buildingequipment. Do not run trolley into endstops.

d) Adjust end limit switch trip.

e) Reverse master switch and repeat (a) to(d).

f) Reset trolley timers, if needed.

28.1.4 Check all Accessories for Proper Function

28.2 No-Load Test

28.2.1 After Reeving the Hoist, Test theOperation of the Hoist Limit Switches as follows

a) Raise empty blocks to within about500 mm of its upper position and stop.

b) Raise the empty block at the lowestcontrol speed until the limit switch tripsand stops the hoisting motion. During thisoperation watch for proper alignmentbetween load block and limit switch trip.

c) Check that block stops at correct height asshown on drawings. Adjust limit switch, ifnecessary.

d) Lower block to 1.5 m.

e) Raise block at about half speed.

f) Check for adequate clearance betweenblock and trolley frame (or upper sheaves).

g) Repeat points (d), (e) and (f) with blockbeing raised at full speed.

28.2.2 If Crane is Equipped with a Lower LimitSwitch, Proceed as follows

a) Lower the empty block until one wrap ofrope remains on each end of the drum.

b) Set lower limit switch to trip at this point(or any higher elevation).

28.2.3 Never lower block beyond the point atwhich one wrap remains at each end of the drum.28.3 Load Test

After the no-load running test has beencompleted, the crane should be tested withloads in the following manner:

a) Raise a load equal to about 50 percent ofthe rated load not higher than required toclear its supports and stop adjust brake, ifnecessary. Raise load about 1 m above itssupports and stop. Lower the load about300 mm and stop. Check drift of loadduring stopping.If load drifts, brakes are not in properadjustment and should be corrected.Repeat this operation until properadjustment of brakes is obtained. Lowerload carefully back to its supports.

b) Load the hoist motion with 100 percent ofrated capacity and follow the sameprocedure as mentioned in (a).

c) Load the hoist motion with 125 percent ofrated capacity, lift the load for 1 M heightand then lower the load.

i) Then hoist the load high enough to clearall obstructions but not higher thannecessary. Move trolley across theentire span of bridge. Transport the testload by means of the bridge for fulllength of the runway in one directionwith the trolley at the extreme righthand end of the crane, and in the otherdirection with the trolley at the extremeleft hand end of the crane.

ii) Measure the deflection when the trolleywith test load is at the middle of thegirder and at extreme end of the girder.Check whether the deflection is withinthe allowable limit.

iii) Measure the ‘No-Load’ and ‘Full Load’current of the motor and verify whetherit is as per the recommendations ofmotor manufacturers.Check the resistors in the circuitwhether any over-heating of theelement occurs.

iv) If separate creep speed control isprovided it should be run for check-outover a distance of about 500 mm.

v) Check overload relays for proper function.

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REPORT OF RADIOGRAPHIC EXAMINATION OF WELDS

Project ...............................................................................................................................................

Quality requirements — Section No. ...............................................................................................

Reported to .......................................................................................................................................

WELD LOCATION AND IDENTIFICATION SKETCH

Technique source ...............................Film to source ....................................Exposure time ....................................Screens ...............................................Film type ............................................

(Describe length, width and thickness of all joints radiographed)

Date Weld Identification Area Interpretation Repairs Remarks

Accept Reject Accept Reject

We, the undersigned, certify that the statements in this record are correct and that the welds wereprepared and tested in accordance with the requirements of AWS Specification D 14.1

Radiographer(s) ..............................................

Interpreter ......................................................

Test date ..........................................................

Manufacturer or Contractor ...........................

Authorized by ..................................................

Date .................................................................

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REPORT OF MAGNETIC PARTICLE EXAMINATION OF WELDS

Project ...............................................................................................................................................

Quality requirements — Section No. ...............................................................................................

Reported to .......................................................................................................................................

WELD LOCATION AND IDENTIFICATION SKETCH

Date Weld Identification Area Interpretation Repairs Remarks

Accept Reject Accept Reject

We, the undersigned, certify that the statements in this record are correct and that the welds wereprepared and tested in accordance with the requirements of AWS Specification D 14.1

Inspector ......................................................

Test date ..........................................................

Manufacturer or Contractor ...........................

Authorized by ..................................................

Date .................................................................

Method of Inspection :

1. Dry 2. Wet 3. Residual 4. Continuous 5. ac 6. dc 7. Half-wave

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DYE PENETRANT INSPECTION REPORT

Customer ...........................................................

Order No. ...........................................................

Drawing No. ......................................................

Date ...................................................................

Material .............................................................

Specification ......................................................

Places Description Comments

Soak time .........................................................................................

The above parts have been carefully tested with dye penetrant. This inspection is limited to defectsof the type which can normally be located with the dye penetrant inspection method.

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ANNEX A( Clause 4.1.1 )

INFORMATION TO BE SUPPLIED WITH ENQUIRY

The purchaser shall supply the followinginformation with the enquiry or order. Wherethe purchaser is unable to fill any particularportion or he wants crane manufacturer tospecify, the requirement shall be made thesubject of agreement between the purchaserand the manufacturer to specify, therequirement shall be made subject ofagreement between the purchaser and themanufacturer.

A-1 GENERAL

1) Crane to be ......... Bay/Department .......installed at

2) No. of cranes ....................................

3) Capacity

Main Hoist ......................... tonnes

Auxiliary Hoist ......................... tonnes

4) Type of crane ....................................

5) Span (centre to ............................. mmcentre of rails)

6) Location : Indoor/ ....................................Outdoor/Both

7) Nature of load ...................................

NOTE — In the case of magnet and grabbing cranes, thespecification and physical condition of the material to behandled shall be given.

8) Altitude of the place :(Where the crane is to be installed)

A-2 CLASSIFICATION

A-2.1 Where detail information is available ofthe operations and of the individual loads to becarried at each stage of the operations.

A-2.2 Where insufficient information isavailable of the operations, classification shallbe as follows:

Main hoist .................................................

Auxiliary hoist ..........................................

Traverse .....................................................

Travel .........................................................

Crane structure ..........................................

A-3 CRANE PERFORMANCE

A-3.1 Speed of Operation

A-3.2 Vertical Movement of Hook

Above floor ......... MBelow floor ......... M

A-4 COMPONENT DETAILS

A-4.1 Rope Drum Details

Utilization:

Main hoist — Average lift ... M; No. of lifts/h ...

Aux hoist — Average lift ... M; No. of lifts/h ...

Traverse — Average ...... M; No. of move/h ....movement

Travel — Average ...... M; No. of move/h ....movement

Crane — Operating h/day ...........Operating h/month ..................Operating h/year .........................

Loads — Actual loads, if known ..........................or percent lifts with approximatelyfull load

Percent of lifts with approximately 75percent load including

....

Percent of lifts with approximately 50percent load lifting

....

Percent of lifts with approximately 25percent load attachment

....

Weight of lifting attachment ...............................

Full Speed M/Min

Creep Speed M/Min

Main hoist ................ ................

Auxiliary hoist ................ ................

Traverse ................ ................

Travel ................ ................

a) Material ...................................

b) Diameter ...................................

c) Length ...................................

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A-4.10 Type of Buffers Required (Spring type/Hydraulic)

For crab ..........For long travel ...........

d) Flange/Flangeless ...................................

A-4.2 Rope Details Main Hoist Aux Hoist

a) Rope construction ............ ............

b) Tensile strength ............ ............

c) Diameter of the rope ............ ............

d) Length of the rope ............ ............

e) No. of falls ............ ............

A-4.3 Sheaves DetailsMain HoistAux Hoist

a) Material ............ ............

b) Diameter of the sheaves (Main)

............ ............

c) Diameter of the sheaves (Equaliser)

............ ............

d) Type of guards provided

............ ............

A-4.4 Coupling Details (Between Motor and Gear Box)

Main Hoist Aux Hoist

a) Type of coupling ............ ............

b) Torque rating ............ ............

c) Size ............ ............

A-4.4.1 Coupling Details (Between Gear Box and Rope Drum)



b) Torque rating ............ ............

c) Size ............ ............

A-4.4.2 Coupling Details (Between Gear Box and Wheels)



b) Torque rating ............ ............

c) Size ............ ............

A-4.5 Gear Box Details M.H. A.H. C.T. L.T.

a) Type of mounting (Horizontal/Vertical)

..... ..... ..... .....

b) Classification ..... ..... ..... .....

c) Total No. of reduction ..... ..... ..... .....

d) Reduction ratio ..... ..... ..... .....

e) Type of lubrication (grease/splash/pump lubrication)

..... ..... ..... .....

f) Hardness (BHN) (Gear/Pinion)

..... ..... ..... .....

g) Materials — Gears/ Pinion

..... ..... ..... .....

h) Casting/Fabricated ..... ..... ..... .....

k) Type and size of bearings in each stage

..... ..... ..... .....

m) kW rating ..... ..... ..... .....

A-4.6 Type of Drive Arrangement (Vertical/Horizontal)

M.H. A.H. C.T. L.T.

A-4.7 Wheel Details

Long Travel Cross Travel

a) Material ............ ............

b) Hardness ............ ............

c) Depth of hardness

............ ............

d) Diameter ............ ............

e) Process of hardening

............ ............

A-4.8 Brakes M.H. AH. C.T. LT.

a) Diameter of the brake ....... ....... ....... .......

b) Torque rating ....... ....... ....... .......

c) Type of brake (ac/dc/Thrustor)

....... ....... ....... .......

A-4.9 Type of Lifting Hooks (C type/ Rams horn)

Main Hoist Aux. Hoist

Safety latch on hook .............. ..............

required/not required

Locking device on : swiveling hook required/not required

.............. ..............

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A-4.11 Type of Bridge Girder Required

A-4.12 Type of Platforms Required on Bridge

A-4.13 Type of Operator’s Cabin :

Fixed/Moving and open/glazed

A-5 ELECTRICAL DETAILS

A-5.1 Power Supply at the Crane Long Travel Collectors

ac or dc Voltage ........ (nominal) + ....... percent

No. of phases ...... frequency Hz + ........ percent

No. of conductors ...............................................

Neutral: Existing/Not existing .........................

Type of earthing provided .................................

Long travel conductors ......................................

a) Length ...........................................

b) Size ...........................................

Long travel collectors by : Purchaser/ Manufacturer

A-5.2 Controls

Whether control is from cabin/pendant/non-conductive

a) Remote control ..............................................

b) Cabin operated ..............................................

c) Pendant : Suspended from crab/fixedpoint on bridge

d) Type of pendant .............................................

e) Type of remote control ...................................

f) Limited range required: Distance ............. m

g) Warning device provided ..............................

h) Any special control requirements againsteach drive to be indicated

k) Scheme of protection .....................................

m) Requirement of isolating switches andtheir positions

n) Type of monitor controller used, No. ofsteps

A-5.3 Motor Details

(Main Hoist, Aux Hoist, Long Travel and CrossTravel)

a) Approved manufacturers for motors ............

b) Class of insulation and protection ................

c) Duty classification .........................................

d) Frame size .....................................................

e) Speed ..............................................................

f) kW rating .......................................................

A-5.4 Main Hoist Limit Switches/Aux. Hoist Limit Switches

a) Shunt/Counterweight ...................................

b) Control voltage/power ...................................

A-5.5 Load Weighing System (Load Cell)

A-5.6 Type of Traverse Current Collection System

A.5.7 Details of Bridge Lighting, Underbridge Lighting Provided, Warning Lights and/or Alarm System Provided

a) Size ...................................

b) Type of connection to the end carriage

...................................

c) Width ...................................

d) Length ...................................

Position of access points ...................................

Emergency escape ...................................

Type of access platform to cabin

...................................

Width of platforms ...................................

Location on bridge fixed if, ................................

Type of fire extinguisher provided

................................

Seating arrangement ................................

Position of controllers ................................

a) Compression type ...............................

b) Tension type ...............................

c) Display unit ...............................

A-5.5.1 Resistance Details M.H. A.H. C.T. L.T.

a) Type ..... ..... ..... .....

b) Rating ..... ..... ..... .....

c) Steps ..... ..... ..... .....

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A-5.8 Cabin Facility Provided by

Fan/Air-conditioning/Cabin heating/others

A-6 ENVIRONMENTAL REQUIREMENTS

A.6.1 General State of Atmosphere or Climate

A.6.2 Average Ambient Temperature

A-7 SPECIAL SERVICE CONDITIONS

a) Use in saline atmospheres the degree ofexposure should be stated.

b) The presence of any local heat sources suchas furnaces or radiant space heatingpanels.

c) The need for special precautions againsttermites.

d) Any physical obstructions not apparentfrom the dimensions provided forclearances.

e) In the case of floor pendant controlledcranes, any differences in the operatingfloor level.

f) Any requirement concerning head roomabove servicing platforms.

g) Wind loading.

h) Any other abnormal atmosphere.

j) Any other conditions.

k) Are there other cranes Yes / Noon the same gantry or in the vicinity ?

If yes whether special devices are required toprevent collision of the cranes or their loads orfor separating the cranes by a minimumdistance in order not to cover stress the gantrystructure.

A-8 DETAILS OF LUBRICATION

A-9 DETAILS OF WIND CLAMPS

A-10 STRUCTURAL DETAILS

A-10.3 Wheel Loads

A-10.4 Dimensions ( see Fig. 2A and 2B )

Span S ............... m; +A2 ........................... mm

Hook travel for

Position of hook from centre line of rails for

Vertical clearance under side bridge ....... K-mm

Position/Height of

Highest point of obstruction L1 ... mm L2 .. mm

Any other site restrictions

A-11 PAINTING

Maximum temperature ...................... °C

Minimum temperature ...................... °C

Maximum humidity ...........................

a) Type (group/centralised) ...........................

b) Capacity ...........................

a) Type (Mechanical/Motorised) ....................

b) Type of interlocking system ....................

A.10.1 Gantry : Existing/New, size .................

A-10.2 Rail : Size of rail .................

a) Minimum wheel load ............................

b) Maximum wheel load ............................

c) Spacing of wheels ............................

Width of rail head B ........ mm

Side clearances X ....... mm Y ...... mm

Z ....... mm

Clearances from any obstruction from top of rail C .................. mm

Rail height from floor D .................. mm

Dimensions of knee bracking on truss

P1 ........................ mm

T1 ........................ mm

P2 ............. mm

T2 ............. mm

Main hoist H1 .......... mm H2 ............ mm

Auxiliary hoist H3 .......... mm H4 ............ mm

Main hoist E ............ mm F .............. mm

Auxiliary hoist E1 .......... mm F1 ............ mm

Cabin L ........... mm M ............. mm

Size of cabin N ........... mm Width ...... mm

a) Prime coat ........................................

b) Two finishing coat ........................................

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A-12 ANY SPECIAL STATUTORY OR TECHNICAL REQUIREMENT

ANNEX B( Clause 4.1.2 )

DETERMINATION OF FATIGUE REFERENCE STRESS

B-1 GENERAL

A fatigue reference stress is used in the processof evaluating the fatigue strength. This annexoutlines a method of determining the fatiguereference stress for component detail. Someguidance is given here for more usual cases onthe determination of limit stresses not to beexceeded, in terms of the cycle of variation ofloading to which the component detail underconsideration is submitted and of the variousfactors which influence the resistance of partsto fatigue.

B-2 FATIGUE REFERENCE STRESS Pfr

Pfr = Cfr × fult

where

B-3 DETERMINATION OF FATIGUE REFERENCE STRESS FACTOR ‘Cfr’

For steel having minimum ultimate tensilestress not greater than 1 100 N/mm the factorCfr can be determined from the followingformulae in which N is the total number ofcycles.

For N ≥ 106 ; Cfr = Clim × B1

For 103 < N < 106 Cfr = AClim

where

A = 1 + B2 for bending stresses

A = 3 for torsion shear stress

B1 =

B2 =

B-4 FATIGUE LIMIT FACTOR Clim

The fatigue limit factor Clim is the value of Cfrcorresponding to the fatigue endurance limit:

where

B-5 DETERMINATION OF C1, C2, C3, Kf AND Kc FACTOR

B-5.1 Stress Factor C1

The value of C1 is given in accordance with thenature of the stress cycle as follows:

C1 = 0.85 for unidirectional bending

0 < fmin / fmax ≤ 1

C1 = 0.50 for reversing bending – 1 ≤ fmin / fmax < 0

C1 = 0.50 for unidirectional torsion 0 < fmin /fmax ≤ 1

C1 = 0.30 for reversing torsion – 1 ≤ fmin / fmax < 0

a) Total weight of the crane (in MT)

.............................

b) Weight of the girder .............................

c) Weight of the girder and platform

.............................

d) Weight of the end carriage with wheels

.............................

e) Weight of the trolley .............................

f) Trolley span .............................

g) Weight of the cabin .............................

h) Type of festooned cable system

.............................

fult = minimum ultimate tensile stress ofthe material, and

Cfr = fatigue reference stress factor.

C1 = stress state factor,C2 = size factor,C3 = surface finish factor,Kf = fatigue notch factor equal to Kbf for

bending, andKc = factor for the miscellaneous effect.

log N3---- 1–

log N6---- 1–

ClimC1

C2 C3× Kf× Kc×----------------------------------------------=

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B-5.2 Size Factor C2

The size factor is derived from Fig. 4.

B-5.3 Surface Finish Factor C3

The surface finish factor is dependent on theultimate tensile stress of the material and themachining process used in manufacturing. Thevalue of C3 is given in Fig. 5 in which Rt is thepeak to valley height of surface roughness inmicro mm.

B-5.4 Fatigue Notch Factor Kbf, Ksf

The presence of such details as shoulders,grooves, holes, key-ways, threads, etc, result ina modification of the simple stress distributionthat would occur in members which have aconstant cross section with gradual changes incontour. The resulting localization of highstresses is measured by the stressconcentration factor defined as follows:

for bending stresses

for torsional shear stress

where

fb Max and fs Max = maximum stresses in acomponent detail, and

fb Nom and fs Nom = nominal stresses at thecorresponding location (without consideringthe effect of notch).

The effect of a notch on the fatigue strengthof a part varies considerably with materialand notch geometry and is normally lessthan would be predicted by the use of thestress concentration factor. The generalphenomenon is denoted as notch sensitivity.For the design purposes following relationsapply :

Kbf = q ( Kb – 1 ) + 1

Ksf = q ( Kb – 1 ) + 1

where

q = notch sensitivity factor.

For the ductile materials the value of ‘q’ may beobtained from established reference works orfrom experimental data. Where no data exists,a value of q = 1.0 should be used in deriving Kbfand Ksf. For brittle material q = 1.0 shall beused in all cases.

Stress concentration factors Kb and Ks are to beobtained from established reference works. Forthe treatment of multiple stress concentrationsin close proximity, reference should be made toestablished reference works.

B-5.5 Factor for Miscellaneous Effects Kc

Corrosion, electrolytic plating, metal sprayingand residual stresses can have a veryappreciable effect on the endurance limit ofsteels under certain conditions. Factor formiscellaneous effect Kc is to be obtained fromestablished reference works.

ANNEX C

NOTES ON DESIGN AND SELECTION OF MOTORS

C-1 SELECTION OF MOTORS FOR HOIST MOTIONS

For hoisting motor the power required shall notbe less than that computed from the following:

where

Kbfb Maxfb Nom----------------=

Ksfs Maxfs Nom----------------=

dc rating factor will be taken as 12 percent,

kW = one hour power rating for dc motorsand power rating at (S – 40 percent)cyclic duration factor for a.c. motors,

kWMVCv Cdf

6.12 E---------------------------- 1

Camb--------------×=

M = mass of the rated load on the hookplus weight of the hook block and thewire ropes in tonnes,

V = specified hoisting speed in M/min,

E = combined efficiency of gears andsheaves

= (0.93)n × (0.98)m for sleeve bearings,

= (0.95)n × (0.99)m for anti-frictionbearings,

= (0.985)n × (0.99)m for hardened profileground and oilsplashed lubricator

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where

For an ac hoist motor, the specified full loadhoist speed must be obtained at not more thanrated torque, therefore, the calculated full loadkW must be multiplied by :

Where sufficient information is not availablevalues given in Table 20B for duty cycles, cyclicduration factor and starting classcorresponding to mechanism class shall beused.

The values given are based on the followingformula:

Cyclic durationfactor =

The starting class ( C ) assumes numbers ofcomplete starts ( S ), jogging operations ( J )and electrical braking operations ( B ) asfollows:

C = S + K1J + K2B

where

Table 20B Recommended Cyclic Duration Factor and Starting Class

( Clause C.1 )

C-2 MOTOR FOR CRANE TRAVEL OR TROLLEY TRAVERSE

C-2.1 General

It is assumed that the drive mechanism fromthe motor to the track wheels will use enclosedgearings mounted on anti-friction bearings.The actual efficiency of the drive will beadopted in making calculations. Where actualefficiency values are not available the efficiencyof the drive shall be taken in the range of 0.85to 0.9.

For the track wheel with anti-friction bearingsthe rolling friction at these bearings plus thefriction between the track wheels with anaverage drive efficiency of 0.875 will give anoverall friction factor of 8.0 kgf per tonne of themass moved for calculation of the motor horsepower or torque. In the case of wheels with theplain bearings an overall friction factor of13.0 kgf per tonne of the mass moved may beused.C-2.2 Selection of Motors for Crane Travel or Trolley Traverse

For bridge travel or trolley traverse the powerof the motor required shall not be less than thatcomputed from the following:

for indoor

cranes

n = number of pairs of gears,m = total number of rotating sheaves

passed over by each part of themoving rope attached to the drum,

Cv = service factor for vertical motiondepending on type of motors,

= 0.67 for ac motors= 0.5 for dc motors

Cdf = duty factor as defined in 7.4.3, andCamb = derating factor for ambient

temperature as given in theTable 20A.

Table 20A Ambient Temperature for Derating Factor

Ambient Temperature Derating Factor, Camb

40° 1.00

45° 0.95

50° 0.88

55° 0.83

60° 0.75

K1 = 0.25 for slip ring motors

= 0.5 for squirrel cage motors

K2 = 0.8 for slip ring motors

= 3.0 for squirrel cage motors

100 – rated slip percent( )100 – total ohms at full speed percent( )

-------------------------------------------------------------------------------------------------------------

Operating time 100×Operating time idle time+-------------------------------------------------------------------------

Mechanism Class

Duty Cycle Number of

Cyclic Class (C)

Cycles/ hour, percent

RecommendedCyclic

Duration Factorpercent

Starting Class (C)

Equivalent Starts/hour

M1 Up to 5 cycles 25

25 90

M2 Up to 5 cycles 25

25 90

M3 10 to 15 cycles 40

25 150


25 150


25/40 150/300


40 300


60 300


60 300/600

kWMVSCdf6 117T

----------------------- F1 100a 981N

--------------------+ =

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for

out door cranes

where

NOTES

1 Duty cycle, recommended cyclic duration factors andrecommended starting Class for the mechanism classcan be taken from Table 20B.

2 At free running speed the acceleration becomes zero.

3 The gear reduction ratio actually used should bereasonably close to the ideal reduction ratio:

4 In order to limit the acceleration to the specified valueand also to take full advantage of the service factor theelectrical control should be designed to suit the values of‘S’ and ‘T’ actually adopted or values of ‘S’ and ‘T’ shouldbe selected based on electrical controls to be provided.

5 Since the wheels must transmit all acceleration forcesto the crane, to prevent wheel skidding dueconsideration should be given on percent driven wheelsafter acceleration rate has been fixed. The wheelskidding should be checked at no-load conditionsconsidering 20 percent adhesion between wheel and rail.

kW = one hour power rating for d.c. motorsand power rating at 40 percent cyclicduration factor for a.c. motors;

M = mass of crane or trolley plus mass ofmax rated load in tonnes;

V = specified free running speed M/min;

N = mechanical efficiency of gearing. Forspur and helical gears, efficiency tobe taken as 0.95 per reduction. Forhardened and ground gears,efficiency to be taken as 0.985 perreduction.

T = factor introduced by the permissiblemotor torque during accelerationexceeding the motor-rated torque. Asa general guidance value of T may betaken as 1.7 for motors having pullout torque of 275 percent full loadtorque. Lower values of T should betaken for corresponding lower valuesof pull out torque.

F = overall friction factor

= 8 kgf per tonne for wheels onanti-friction bearings

= 13 kgf per tonne for wheels on plainbearings

Cdf = duty factor as defined in 7.4.3;

Rw1 = load due to service wind actinghorizontally as defined in 7.3.1which can be obtained bymultiplying the horizontal exposedarea by the service wind by takingdrag co-efficient into consideration;

a = average linear acceleration of thecrane or the trolley in cm/s2 till themechanism reaches 90 percent offree running speed. For the values ofaverage linear acceleration refer asgiven in Table 21A; and

S = service factor aimed at providingadequate motor heat dissipationcapacity as given in Table 21B.

kWMVSCdf6 117T

----------------------- F 1 100 a 981N

---------------------+ RwV

6 117T-------------------+= Table 21A Acceleration Values

( Clause C-2.2 )

Speed to be

Reached M/min

Condition

Acceleration in cm/s2 Low and Moderate

Speed with Long Travel

Acceleration in cm/s2 for

Moderate and High Speed

(Normal Application)

Acceleration in cm/s2 for High Speed with High

Acceleration

240 — 50 67

190 — 44 58

150 — 39 52

120 22 35 47

100 19 32 43

60 15 25 33

40 12 19 —

25 10 16 —

15 8 — —

10 7 — —

Table 21B Values of Service Factors( Clause C-2.2 )

Bridge Service Factor Trolley Service Factor

Without Plugging With Plugging

0.95 1.00 1.06

Motor rev/min at free runningTrack wheel rev/give specified running speed-----------------------------------------------------------------------------------------------------------------------------=

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ANNEX D

INTERMITTENT RATINGS FOR RESISTORS

D-1 GENERAL

The basis of the rating shall be the ratio of therunning time to a total time of 15 min and theresistors are rated to carry the rated full loadmotor current in any section or sections exceptwhere current is restricted to lower value bythe amount of resistance in the circuit in whichcase the resistor shall be rated to carry thecurrent passed with the motor at stand still.

D-2 DEFINITION OF DIFFERENT RATINGS

D-2.1 Two Minute Rating

A resistor having a two minute rating shall becapable of being left in the circuit for a periodnot exceeding 30 s on the first section and for afurther period of 90 s divided between theremaining sections of the resistor, followed by aperiod of rest of 13 min, this cycle beingrepeated until a stable temperature is reached.

D-2.2 Five Minute Rating

A resistor having a five minute rating shall becapable of being left in circuit for a period notexceeding 2 min on the first section and for afurther period of 3 min equally divided betweenthe remaining sections of the resistor, followedby a period of rest of 10 min, this cycle beingrepeated until a stable temperature is reached.

D-2.3 Ten Minute Rating

A resistor having a ten minute rating shall becapable of being left in circuit for a period notexceeding 4 min on the first section and for afurther period of 6 min equally divided betweenthe remaining sections of the resistor, followedby a period of rest of 5 min, this cycle beingrepeated until a stable temperature is reached.

ANNEX E( Clause 18.2 )

CRANE-RECOMMENDED/PREFERRED PARAMETERS

E-1 GENERAL

To aid economic manufacture it isrecommended that the crane parameters givenin F-2 to F-4 be selected from a progressionbased upon the preferred number series.

E-2 PREFERRED LIFTING CAPACITIES

Preferred series R10 shall be used for capacitiesup to and including 125 tonnes and R20 forcapacities above 125 tonnes. The preferredlifting capacities (in tonnes) are as follows:

E-3 PREFERRED LIFTING HEIGHT

Preferred series R5 shall be used for liftingheights up to and including 16 m and R10 forheights above 16 m. The preferred liftingheights (in metres) are as follows:

E-4 PREFERRED SPEED OF OPERATION (FULL SPEEDS)

Preferred series R5 and R10 shall be used forfull speed of operation respectively. Thepreferred speeds of operation (in metres perminute) are as follows:

1.0

1.25

1.6

2.0

2.5

3.2

4.0

5.0

6.3

8.0

10

12.5

16

20

25

32

40

50

63

80

100

125

140

160

200

225

250

280

320

360

400

450

500

560

etc.

2.5

4.0

6.3

10

16

20

25

32

40

50

63

etc.

0.63

0.8

1.0

1.25

1.6

2.0

2.5

3.2

4.0

5.0

6.3

8.0

10

12.5

16

20

25

32

40

50

63

80

100

125

160

200

—

—

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ANNEX F( Clause 2.1 )

LIST OF INDIAN STANDARDS

F-1 MATERIALS

F-1.1 Steels and Castings and Tubes

IS No. Title

210 : 1993 Specification for grey ironcastings ( fourth revision )

1030 : 1989 Specification for carbon steelcastings for generalengineering purposes ( fourthrevision )

1239 Mild steel tubes, tubular andother wrought steel fittings:

(Part 1) : 1990 Mild steel tubes ( fifthrevision )

(Part 2) : 1992 Mild steel tubular and otherwrought steel pipe fittings( fourth revision )

1387 : 1993 General requirements for thesupply of metallurgicalmaterials ( second revision )

1570 : 1961 Schedule for wrought steel forgeneral engineering purposes

2062 : 1992 Specification for steel forgeneral structural purposes( fourth revision )

F-1.2 Threaded Fasteners

1364 Specification for hexagon headbolts, screws and nuts ofproduct grades A and B:

(Part 1) : 1992 Hexagon head bolts (sizerange M1.6 to M64) ( thirdrevision )

(Part 2) : 1992 Hexagon head screws (sizerange M1.6 to M64) ( thirdrevision )

(Part 3) : 1992 Hexagon head nuts (size rangeM1.6 to M64) ( third revision )

(Part 4) : 1992 Hexagon thin nuts(chamfered) (size range M1.6to M64) ( third revision )

(Part 5) : 1992 Hexagon thin nuts(unchamfered) (size rangeM1.6 to M10) ( third revision )

IS No. Title

1367 Technical supply conditionsfor threaded fasteners:

(Part 6) : 1994 Mechanical properties andtest methods for nuts withspecified proof loads ( thirdrevision )

(Part 7) : 1980 Mechanical properties andtest methods for nuts withoutspecified proof loads ( secondrevision )

(Part 9/Sec 2) : 1979

Surface discontinuities,Section 2 Bolts, screws andstuds for special application( second revision )

(Part 10) : 1979 Surface discontinuities onnuts ( second revision )

(Part 12) : 1981 Phosphate coating onthreaded fasteners ( secondrevision )

(Part 13) : 1983 Hot-dip galvanized coatingson threaded fasteners( second revision )

(Part 14) : 1984 Stainless steel threadedfasteners ( second revision )

(Part 16) : 1979 Designation system andsymbols ( first revision )

(Part 18) : 1979 Marking and mode ofdelivery ( second revision )

3640 : 1982 Hexagon fit bolts ( firstrevision )

3757 : 1985 High strength structuralbolts ( second revision )

6639 : 1972 Hexagonal bolts for steelstructures

F-1.3 Wire Rope

1856 : 1977 Specification for steel wireropes for haulage purposes( second revision )

2266 : 1989 Specification for steel wireropes for general engineeringpurpose ( third revision )

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IS No. Title

2365 : 1977 Specification for steel wire ropesfor lifts, elevators and hoists( first revision )

2762 : 1982 Specification for wire ropeslings and sling legs ( firstrevision )

3973 : 1984 Code of practice for selection,installation and maintenance ofwire ropes ( first revision )

6594 : 1977 Technical supply conditions forsteel wire ropes and strands( first revision )

F-2 MECHANICAL AND FABRICATION DETAILS

F-2.1 Key and Key-ways

2048 : 1983 Specification of parallel keysand key-ways ( second revision )

2291 : 1981 Specification for tangential keysand key-ways ( second revision )

2292 : 1974 Specification for taper keys andkey-ways ( first revision )

2294 : 1986 Specification for woodruff keysand key-ways ( second revision )

6166 : 1971 Specification for thin taper keyand key-ways

6167 : 1971 Specification for parallel keysand key-ways

F-2.2 Welding

816 : 1969 Code of practice for use of metalarc welding for generalconstruction in mild steel ( firstrevision )

818 : 1968 Code of practice for safety andhealth requirements in electricand gas welding and cuttingoperation ( first revision )

822 : 1970 Code of procedure for inspectionof welds

1024 : 1979 Code of practice for use ofwelding in bridges andstructures subject to dynamicloading ( first revision )

IS No. Title

1323 : 1982 Code of practice foroxyacetylene welding forstructural work in mild steel( second revision )

9595 : 1980 Recommendations for metal arcwelding of carbon and carbonmanganese steels

F-2.3 Gears

2467 : 1963 Notation for toothed gearing

2535 : 1978 Basic rack and modules ofcylindrical gears for generalengineering and heavyengineering ( second revision )

3734 : 1983 Dimensions for worm gearing( first revision )

4460 : 1967 Method for rating of machinecut spur and helical gears

5037 : 1969 Basic rack and modules ofstraight bevel gears for generalengineering and heavyengineering

6535 : 1979 Data for procurement ofstraight bevel gears ( firstrevision )

7403 : 1974 Code of practice for selection ofstandard worm and helical gearboxes

7504 : 1974 Methods of inspection of spurand helical gear

10911 : 1984 Method of inspection forstraight bevel gears

F-3 ELECTRICAL DETAILS

F-3.1 Motors

325 : 1978 Specification for three-phaseinduction motors ( fourthrevision )

900 : 1992 Code of practice for installationand maintenance of inductionmotors ( revised )

1231 : 1974 Dimensions of three-phase footmounted induction motors( third revision )

2223 : 1983 Dimensions of flange mountedac-induction motors ( secondrevision )

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IS No. Title

2253 : 1974 Designation for types ofconstruction and mountingarrangement of rotatingelectrical machines ( firstrevision )

4691 : 1985 Degrees of protection providedby enclosure for rotatingelectrical machinery ( firstrevision )

4722 : 1968 Specification for rotatingelectrical machines

4728 : 1975 Terminal marking anddirection of rotation forrotating electrical machinery( first revision )

12065 : 1987 Permissible limits of noiselevel for rotating electricalmachines

F-3.2 Cables and Conductors

9968 Specification for elastomersinsulated cables :

(Part 1) : 1988 For working voltages up toand including 1 100 V ( firstrevision )

(Part 2) : 1981 For working voltages from 3.3kV upto and including 11 kV

694 : 1977 Specification for PVCinsulated cables for workingvoltages up to and including1 100 V ( second revision )

1554 Specification for PVCinsulated (heavy duty) electriccables:

(Part 1) : 1988 For working voltages up toand including 1 100 V ( thirdrevision )

(Part 2) : 1981 For working voltages from 3.3kV up to and including 11 kV( second revision )

8130 : 1984 Specification for conductorsfor insulated electric cablesand flexible cords ( firstrevision )

F-3.3 Switch Gear

2516 :(Parts 1 & 2/ Sec 1) : 1985

Specification for circuitbreakers : Parts 1 & 2Requirements and tests,Section 1 Voltages notexceeding 1 000 V ac or 1 200dc ( second revision )

IS No. Title

3427 : 1969 Specification for metal-enclosed switchgear andcontrol gear for voltages above1 000 V but not exceeding11 000 V

8544 Specification for motorstarters for voltages notexceeding 1 000 V:

(Part 1) : 1977 Direct-on-line ac starters

(Part 2) : 1977 Star-delta starters

(Part 3/Sec 2) : 1977

Rheostatic motor starters,Section 2 Additionalrequirements for ac rheostaticmotor controllers

(Part 4) : 1979 Reduced voltages AC-starters,two-step auto transformerstarters

10118 Code of practice for selection,installation and maintenanceof switchgear and controlgear:

(Part 1) : 1982 General

(Part 2) : 1982 Selection

(Part 3) : 1982 Installation

(Part 4) : 1982 Maintenance

13947(Part 1) : 1993

Low-voltage switchgear andcontrolgear : Part 1 Generalrules

13118 : 1991 High voltage alternatingcurrent circuit breakers

F-3.4 Earthing

3043 : 1987 Code of practice for earthing

F-3.5 Conduits

9537 Conduits and electricalinstallations:

(Part 1) : 1980 General requirements

(Part 2) : 1980 Rigid steel conduits

(Part 3) : 1981 Rigid plain conduits ofinsulating materials

(Part 4) : 1983 Pliable self-recoveringconduits of insulatingmaterials

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IS No. Title

F-3.6 Cranes

807 : 1976 Code of practice for design,manufacture, erection andtesting (structural portion) ofcranes and holes ( firstrevision )

4137 : 1985 Code of practice for heavy dutyelectric overhead travellingcranes including special servicemachines for use in steel work( first revision )

4728 : 1975 Terminal marking and directionof rotation for rotating electricalmachinery ( first revision )

IS No. Title

13743(Part 1) : 1992

Cranes — Vocabulary : Part 1General

13834 Cranes :

(Part 1) : 1994 General

(Part 5) : 1993 Overhead travelling andportal bridge cranes

13870(Part 1) : 1993

Cranes and liftingappliances — Selection of wireropes : Part 1 General

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Bureau of Indian Standards

BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promoteharmonious development of the activities of standardization, marking and quality certification of goods andattending to connected matters in the country.

Copyright

BIS has the copyright of all its publications. No part of these publications may be reproduced in any formwithout the prior permission in writing of BIS. This does not preclude the free use, in the course ofimplementing the standard, of necessary details, such as symbols and sizes, type or grade designations.Enquiries relating to copyright be addressed to the Director (Publications), BIS.

Review of Indian Standards

Amendments are issued to standards as the need arises on the basis of comments. Standards are alsoreviewed periodically; a standard along with amendments is reaffirmed when such review indicates that nochanges are needed; if the review indicates that changes are needed, it is taken up for revision. Users ofIndian Standards should ascertain that they are in possession of the latest amendments or edition byreferring to the latest issue of ‘BIS Catalogue’ and ‘Standards : Monthly Additions’.

This Indian Standard has been developed from Doc : No. HMD 14 (0262).

Amendments Issued Since Publication

Amend No. Date of Issue

Amd. No. 1 December 2000

Amd. No. 2 July 2003

BUREAU OF INDIAN STANDARDS

Headquarters:

Manak Bhavan, 9 Bahadur Shah Zafar Marg, New Delhi 110002.Telephones: 323 01 31, 323 33 75, 323 94 02

Telegrams: Manaksanstha(Common to all offices)

Regional Offices: Telephone

Central : Manak Bhavan, 9 Bahadur Shah Zafar MargNEW DELHI 110002

323 76 17323 38 41

Eastern : 1/14 C. I. T. Scheme VII M, V. I. P. Road, KankurgachiKOLKATA 700054

337 84 99, 337 85 61337 86 26, 337 91 20

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832 92 95, 832 78 58832 78 91, 832 78 92

Branches : AHMED ABAD . BANG ALOR E. BHO PAL. BH UBANE SH WAR . C OI MB ATOR E. FARI DA BAD. G HAZI ABA D. GUWAH ATI . H YDER ABAD . JAI PUR . K ANPUR . LUCKNOW. NAGPUR. NALAGARH. PATNA. PUNE. RAJKOT. THIRUVANANTHAPURAM.VISHAKHAPATNAM.

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3177 code practice for oh cranes and gantry cranes

Documents

gantry cranes

cost of cranes

standard assistance

new classification of

forewordthis indian

steel work cranes

international standards

bureau of indian standards